Iron type golf club head

ABSTRACT

Iron-type golf club heads are disclosed having a heel portion, a sole portion, a toe portion, a top-line portion, a front portion, a rear portion, and a striking face. The iron-type golf club heads include a flexible boundary structure (“FBS”) that is provided at one or more locations on the club head. The flexible boundary structure may comprise, in several embodiments, a slot, a channel, a gap, a thinned or weakened region, or other structure that enhances the capability of an adjacent or related portion of the golf club head to flex or deflect and to thereby provide a desired improvement in the performance of the golf club head.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/788,133, filed Feb. 11, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/522,509, filed Jul. 25, 2019, which is acontinuation of U.S. patent application Ser. No. 15/840,922, filed Dec.13, 2017, which is a continuation of U.S. patent application Ser. No.15/448,927, filed Mar. 3, 2017, which is a continuation of U.S. patentapplication Ser. No. 14/719,054, filed May 21, 2015, which is acontinuation of U.S. patent application Ser. No. 13/830,293, filed Mar.14, 2013 (now U.S. Pat. No. 9,044,653, which issued on Jun. 2, 2015),which claims priority to and benefit of U.S. Provisional PatentApplication No. 61/657,675, filed Jun. 8, 2012. All of theseapplications are incorporated by reference herein in their entireties.

FIELD

The present disclosure relates to golf club heads, golf clubs, and setsof golf clubs. More specifically, the present disclosure relates to golfclub heads for iron type golf clubs, and golf clubs and sets of golfclubs including such golf club heads.

BACKGROUND

A golf set includes various types of clubs for use in differentconditions or circumstances in which a ball is hit during a golf game. Aset of clubs typically includes a “driver” for hitting the ball thelongest distance on a course. A fairway “wood” can be used for hittingthe ball shorter distances than the driver. A set of irons are used forhitting the ball within a range of distances typically shorter than thedriver or woods. Every club has an ideal striking location or “sweetspot” that represents the best hitting zone on the face for maximizingthe probability of the golfer achieving the best and most predictableshot using the particular club.

An iron has a flat face that normally contacts the ball whenever theball is being hit with the iron. Irons have angled faces for achievinglofts ranging from about 18 degrees to about 64 degrees. The size of aniron's sweet spot is generally related to the size (i.e., surface area)of the iron's striking face, and iron sets are available with oversizeclub heads to provide a large sweet spot that is desirable to manygolfers. Most golfers strive to make contact with the ball inside thesweet spot to achieve a desired ball speed, distance, and trajectory.

Conventional “blade” type irons have been largely displaced (especiallyfor novice golfers) by so-called “perimeter weighted” irons, whichinclude “cavity-back” and “hollow” iron designs. Cavity-back irons havea cavity directly behind the striking plate, which permits club headmass to be distributed about the perimeter of the striking plate, andsuch clubs tend to be more forgiving to off-center hits. Hollow ironshave features similar to cavity-back irons, but the cavity is enclosedby a rear wall to form a hollow region behind the striking plate.Perimeter weighted, cavity back, and hollow iron designs permit clubdesigners to redistribute club head mass to achieve intended playingcharacteristics associated with, for example, placement of club headcenter of mass or a moment of inertia. These designs also permit clubdesigners to provide striking plates that have relatively large faceareas that are unsupported by the main body of the golf club head.

SUMMARY OF THE DESCRIPTION

The present disclosure describes iron type golf club heads typicallycomprising a head body and a striking plate. The head body includes aheel portion, a toe portion, a topline portion, a sole portion, and ahosel configured to attach the club head to a shaft. In someembodiments, the head body defines a front opening configured to receivethe striking plate at a front rim formed around a periphery of the frontopening. In other embodiments, the striking plate is formed integrally(such as by casting) with the head body.

Some embodiments of the iron type golf club heads include a flexibleboundary structure (“FBS”) provided at one or more locations on the clubhead. The flexible boundary structure may comprise, in severalembodiments, a slot, a channel, a gap, a thinned or weakened region, orother structure that enhances the capability of an adjacent or relatedportion of the golf club head to flex or deflect and to thereby providea desired improvement in the performance of the golf club head.

In a first aspect, a clubhead for an iron-type golf club includes a bodyhaving a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, with the sole portion extending rearwardlyfrom a lower end of the face portion. The face portion includes an idealstriking location that defines the origin of a coordinate system inwhich an x-axis is tangential to the face portion at the ideal strikinglocation and is parallel to a ground plane when the body is in a normaladdress position, a y-axis extends perpendicular to the x-axis and isalso parallel to the ground plane, and a z-axis extends perpendicular tothe ground plane. In the coordinate system, a positive x-axis extendstoward the heel portion from the origin, a positive y-axis extendsrearwardly from the origin, and a positive z-axis extends upwardly fromthe origin. The body includes a central region in which −25 mm<x<25 mm.The sole portion that is contained within the central region includes aforward sole region located adjacent to the face portion and a sole barlocated rearward of the forward sole region, with the forward soleregion defining a wall having a minimum forward sole thickness T_(FS)and the sole bar defining a body having a maximum sole bar thicknessT_(SB), such that 0.05<T_(FS)/T_(SB)<0.4. The sole bar defines a firstchannel extending in a substantially heel-to-toe direction of the soleportion and having a first channel opening located on a bottom surfaceof the sole bar.

In some embodiments, the first channel has a first channel lengthcomprising the distance between a part of the first channel nearest thetoe portion and a part of the first channel nearest the heel region,with the first channel length being from about 15 mm to about 85 mm. Insome additional embodiments, the first channel length is from about 30mm to about 57 mm.

In some embodiments, the first channel has a first channel depthcomprising a vertical distance between the ground plane and an uppermostpoint of the first channel, with an average of the first channel depthwithin the central region being from about 5 mm to about 25 mm. In someadditional embodiments, the first channel depth is substantiallyconstant within the central region.

In some embodiments, the body includes a toe side region wherein thex-axis coordinate is less than −25 mm, and a heel side region whereinthe x-axis coordinate is greater than 25 mm, and the first channel hasan average depth in the central region that is less than an averagedepth of the first channel in the toe side region. In some furtherembodiments, the first channel has an average depth in the centralregion that is less than an average depth of the first channel in theheel side region. Still further, in some embodiments, the first channelhas an average depth in the central region that is less than an averagedepth of the first channel in the toe side region and that is less thanan average depth of the first channel in the heel side region. In stillother embodiments, the first channel has an average depth in the centralregion that is greater than an average depth of the first channel in thetoe side region. In still other embodiments, the first channel has anaverage depth in the central region that is greater than an averagedepth of the first channel in the heel side region. In still otherembodiments, the first channel has an average depth in the centralregion that is greater than an average depth of the first channel in thetoe side region and that is greater than an average depth of the firstchannel in the heel side region.

In some embodiments, the sole bar defines a second channel extending ina substantially heel-to-toe direction of the sole bar and having asecond channel opening located on an upper surface of the sole bar, thesecond channel having a second channel length, a second channel depth,and a second channel width.

In some embodiments, the central region of the body is defined as: −20mm<x<20 mm. In still other embodiments, the central region of the bodyis defined as: −15 mm<x<15 mm.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm. In still other embodiments,1.0 mm<T_(FS)<2.5 mm.

In some embodiments, the first channel has a first channel length L1,the body has a sole length L_(B), and a ratio of the first channellength to the sole length satisfies the following inequality:0.35<L1/L_(B)<0.67.

In some embodiments, the first channel defines a first channel depth H1that comprises the vertical distance from the ground plane to theuppermost point of the first channel, the body defines a body heightH_(CH) that comprises the vertical distance from the ground plane to theuppermost point of the body, and a ratio of an average value of thefirst channel depth H1 within the central region to the body heightH_(CH) satisfies the following inequality: 0.07<H1_(AVG)/H_(CH)<0.50.

In some embodiments, the first channel defines a first channelcenterline and the face portion defines a face plane. In theseembodiments, projections of the first channel centerline and the faceplane onto the ground plane define a face to channel distance D1, thesole portion defines a sole width D3, and a ratio of an average value ofthe face to channel distance D1 within the central region to an averagevalue of the sole width D3 within the central region satisfies thefollowing inequality: 0.15<D1/D3<0.71.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.In some of these embodiments, the body has a volume V that satisfies thefollowing inequality: 40 cc<V<90 cc. In some of these embodiments, thebody has a volume V that satisfies the following inequality: 60 cc<V<80cc.

In some embodiments, the body defines a clubhead depth, D_(CH) thatsatisfies the following inequality: 15 cc<D_(CH)<100 cc. In some ofthese embodiments, the body has a clubhead depth that satisfies thefollowing inequality: 30 cc<D_(CH)<80 cc. In some of these embodiments,the body has a clubhead depth that satisfies the following inequality:40 cc<D_(CH)<70 cc.

In some embodiments, a filler material is located in the first channel.

In a second aspect, a clubhead for an iron-type golf club includes abody having a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, with the sole portion extending rearwardlyfrom a lower end of the face portion. The face portion includes an idealstriking location that defines the origin of a coordinate system inwhich an x-axis is tangential to the face portion at the ideal strikinglocation and is parallel to a ground plane when the body is in a normaladdress position, a y-axis extends perpendicular to the x-axis and isalso parallel to the ground plane, and a z-axis extends perpendicular tothe ground plane. In the coordinate system, a positive x-axis extendstoward the heel portion from the origin, a positive y-axis extendsrearwardly from the origin, and a positive z-axis extends upwardly fromthe origin. The body includes a central region in which −25 mm<x<25 mm.The sole portion that is contained within the central region includes aforward sole region located adjacent to the face portion and a sole barlocated rearward of the forward sole region, the sole bar defining afirst channel extending in a substantially heel-to-toe direction of thesole portion and having a first channel opening located on a bottomsurface of the sole bar. The first channel defines a first channelcenterline and the face portion defines a face plane, such thatprojections of the first channel centerline and the face plane onto theground plane define a face to channel distance D1. The sole portiondefines a sole width D3. A ratio of an average value of the face tochannel distance D1 within the central region to an average value of thesole width D3 within the central region satisfies the followinginequality: 0.15<D1/D3<0.71.

In some embodiments, the forward sole region defines a wall having aminimum forward sole thickness T_(FS) and the sole bar defines a bodyhaving a maximum sole bar thickness T_(SB), such that0.05<T_(FS)/T_(SB)<0.4.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm. In still other embodiments,1.0 mm<T_(FS)<2.5 mm.

In some embodiments, the first channel has a first channel length L1,the body has a sole length L_(B), and a ratio of the first channellength to the sole length satisfies the following inequality:0.35<L1/L_(B)<0.67.

In some embodiments, the first channel defines a first channel depth H1that comprises the vertical distance from the ground plane to theuppermost point of the first channel, the body defines a body heightH_(CH) that comprises the vertical distance from the ground plane to theuppermost point of the body, and a ratio of an average value of thefirst channel depth H1 within the central region to the body heightH_(CH) satisfies the following inequality: 0.07<H1_(AVG)/H_(CH)<0.50.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.In some of these embodiments, the body has a volume V that satisfies thefollowing inequality: 40 cc<V<90 cc. In some of these embodiments, thebody has a volume V that satisfies the following inequality: 60 cc<V<80cc.

In some embodiments, the body defines a clubhead depth, D_(CH) thatsatisfies the following inequality: 15 cc<D_(CH)<100 cc. In some ofthese embodiments, the body has a clubhead depth that satisfies thefollowing inequality: 30 cc<D_(CH)<80 cc. In some of these embodiments,the body has a clubhead depth that satisfies the following inequality:40 cc<D_(CH)<70 cc.

In some embodiments, a filler material is located in the first channel.

In a third aspect, a clubhead for an iron-type golf club includes a bodyhaving a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, with the sole portion extending rearwardlyfrom a lower end of the face portion. The face portion includes an idealstriking location that defines the origin of a coordinate system inwhich an x-axis is tangential to the face portion at the ideal strikinglocation and is parallel to a ground plane when the body is in a normaladdress position, a y-axis extends perpendicular to the x-axis and isalso parallel to the ground plane, and a z-axis extends perpendicular tothe ground plane. In the coordinate system, a positive x-axis extendstoward the heel portion from the origin, a positive y-axis extendsrearwardly from the origin, and a positive z-axis extends upwardly fromthe origin. The sole portion includes a forward sole region locatedadjacent to the face portion and a sole bar located rearward of theforward sole region, with the sole bar defining a first channelextending in a substantially heel-to-toe direction of the sole portionand having a first channel opening located on a bottom surface of thesole bar. The first channel has a first channel length L1, the body hasa sole length L_(B), and a ratio of the first channel length to the solelength satisfies the following inequality: 0.35<L1/L_(B)<0.67.

In some embodiments, the forward sole region defines a wall having aminimum forward sole thickness T_(FS) and the sole bar defines a bodyhaving a maximum sole bar thickness T_(SB), such that0.05<T_(FS)/T_(SB)<0.4.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm. In still other embodiments,1.0 mm<T_(FS)<2.5 mm.

In some embodiments, the first channel defines a first channel depth H1that comprises the vertical distance from the ground plane to theuppermost point of the first channel, the body defines a body heightH_(CH) that comprises the vertical distance from the ground plane to theuppermost point of the body, and a ratio of an average value of thefirst channel depth H1 within the central region to the body heightH_(CH) satisfies the following inequality: 0.07<H1_(AVG)/H_(CH)<0.50.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.In some of these embodiments, the body has a volume V that satisfies thefollowing inequality: 40 cc<V<90 cc. In some of these embodiments, thebody has a volume V that satisfies the following inequality: 60 cc<V<80cc.

In some embodiments, the body defines a clubhead depth, D_(CH) thatsatisfies the following inequality: 15 cc<D_(CH)<100 cc. In some ofthese embodiments, the body has a clubhead depth that satisfies thefollowing inequality: 30 cc<D_(CH)<80 cc. In some of these embodiments,the body has a clubhead depth that satisfies the following inequality:40 cc<D_(CH)<70 cc.

In some embodiments, a filler material is located in the first channel.

In a fourth aspect, a clubhead for an iron-type golf club includes abody having a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, with the sole portion extending rearwardlyfrom a lower end of the face portion. The face portion includes an idealstriking location that defines the origin of a coordinate system inwhich an x-axis is tangential to the face portion at the ideal strikinglocation and is parallel to a ground plane when the body is in a normaladdress position, a y-axis extends perpendicular to the x-axis and isalso parallel to the ground plane, and a z-axis extends perpendicular tothe ground plane. In the coordinate system, a positive x-axis extendstoward the heel portion from the origin, a positive y-axis extendsrearwardly from the origin, and a positive z-axis extends upwardly fromthe origin. The body includes a central region in which −25 mm<x<25 mm.The sole portion that is contained within the central region includes aforward sole region located adjacent to the face portion and a sole barlocated rearward of the forward sole region, the sole bar defining afirst channel extending in a substantially heel-to-toe direction of thesole portion and having a first channel opening located on a bottomsurface of the sole bar. The first channel defines a first channel depthH1 that comprises the vertical distance from the ground plane to theuppermost point of the first channel, the body defines a body heightH_(CH) that comprises the vertical distance from the ground plane to theuppermost point of the body, and a ratio of an average value of thefirst channel depth H1 within the central region to the body heightH_(CH) satisfies the following inequality: 0.07<H1_(AVG)/H_(CH)<0.50.

In some embodiments, the forward sole region defines a wall having aminimum forward sole thickness T_(FS) and the sole bar defines a bodyhaving a maximum sole bar thickness T_(SB), such that0.05<T_(FS)/T_(SB)<0.4.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm. In still other embodiments,1.0 mm<T_(FS)<2.5 mm.

In some embodiments, the first channel has a first channel length L1,the body has a sole length L_(B), and a ratio of the first channellength to the sole length satisfies the following inequality:0.35<L1/L_(B)<0.67.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.In some of these embodiments, the body has a volume V that satisfies thefollowing inequality: 40 cc<V<90 cc. In some of these embodiments, thebody has a volume V that satisfies the following inequality: 60 cc<V<80cc.

In some embodiments, the body defines a clubhead depth, D_(CH) thatsatisfies the following inequality: 15 cc<D_(CH)<100 cc. In some ofthese embodiments, the body has a clubhead depth that satisfies thefollowing inequality: 30 cc<D_(CH)<80 cc. In some of these embodiments,the body has a clubhead depth that satisfies the following inequality:40 cc<D_(CH)<70 cc.

In some embodiments, a filler material is located in the first channel.

In a fifth aspect, a set of iron-type golf clubs includes a first subsetof at least one iron-type golf club and a second subset of at least oneiron-type golf club. The first subset includes at least one club headwith a loft that is less than or equal to 30°, a face portion, a heelportion, a toe portion, a sole portion, and a top-line portion, with thesole portion defining a flexible boundary structure comprising a slot ora channel having a length of from about 15 mm to about 85 mm. The secondsubset includes at least one club head with a loft that is greater than30°, a face portion, a heel portion, a toe portion, a sole portion, anda top-line portion, with the sole portion having no flexible boundarystructure comprising a slot or a channel having a length of from about15 mm to about 85 mm.

In some embodiments, the first subset includes at least two golf clubs,at least three golf clubs, at least four golf clubs, or at least fivegolf clubs. In some embodiments, the second subset includes at least twogolf clubs, at least three golf clubs, at least four golf clubs, or atleast five golf clubs.

In some embodiments, each of the golf clubs of the first subset includesa body having a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, with the sole portion extending rearwardlyfrom a lower end of the face portion. The face portion includes an idealstriking location that defines the origin of a coordinate system inwhich an x-axis is tangential to the face portion at the ideal strikinglocation and is parallel to a ground plane when the body is in a normaladdress position, a y-axis extends perpendicular to the x-axis and isalso parallel to the ground plane, and a z-axis extends perpendicular tothe ground plane. In the coordinate system, a positive x-axis extendstoward the heel portion from the origin, a positive y-axis extendsrearwardly from the origin, and a positive z-axis extends upwardly fromthe origin. The body includes a central region in which −25 mm<x<25 mm.The sole portion that is contained within the central region includes aforward sole region located adjacent to the face portion and a sole barlocated rearward of the forward sole region, with the forward soleregion defining a wall having a minimum forward sole thickness T_(FS)and the sole bar defining a body having a maximum sole bar thicknessT_(SB), such that 0.05<T_(FS)/T_(SB)<0.4. The sole bar defines a firstchannel extending in a substantially heel-to-toe direction of the soleportion and having a first channel opening located on a bottom surfaceof the sole bar.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm. In still other embodiments,1.0 mm<T_(FS)<2.5 mm.

In some embodiments, the first channel has a first channel length L1,the body has a sole length L_(B), and a ratio of the first channellength to the sole length satisfies the following inequality:0.35<L1/L_(B)<0.67.

In some embodiments, the first channel defines a first channel depth H1that comprises the vertical distance from the ground plane to theuppermost point of the first channel, the body defines a body heightH_(CH) that comprises the vertical distance from the ground plane to theuppermost point of the body, and a ratio of an average value of thefirst channel depth H1 within the central region to the body heightH_(CH) satisfies the following inequality: 0.07<H1_(AVG)/H_(CH)<0.50.

In some embodiments, the first channel defines a first channelcenterline and the face portion defines a face plane. In theseembodiments, projections of the first channel centerline and the faceplane onto the ground plane define a face to channel distance D1, thesole portion defines a sole width D3, and a ratio of an average value ofthe face to channel distance D1 within the central region to an averagevalue of the sole width D3 within the central region satisfies thefollowing inequality: 0.15<D1/D3<0.71.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.In some of these embodiments, the body has a volume V that satisfies thefollowing inequality: 40 cc<V<90 cc. In some of these embodiments, thebody has a volume V that satisfies the following inequality: 60 cc<V<80cc.

In some embodiments, the body defines a clubhead depth, D_(CH) thatsatisfies the following inequality: 15 cc<D_(CH)<100 cc. In some ofthese embodiments, the body has a clubhead depth that satisfies thefollowing inequality: 30 cc<D_(CH)<80 cc. In some of these embodiments,the body has a clubhead depth that satisfies the following inequality:40 cc<D_(CH)<70 cc.

In a sixth aspect, a clubhead for an iron-type golf club includes a bodyhaving a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, wherein said sole portion extendsrearwardly from a lower end of said face portion, the body furtherdefining a rear void. The face portion includes an ideal strikinglocation that defines the origin of a coordinate system in which anx-axis is tangential to the face portion at the ideal striking locationand is parallel to a ground plane when the body is in a normal addressposition, a y-axis extends perpendicular to the x-axis and is alsoparallel to the ground plane, and a z-axis extends perpendicular to theground plane. In the coordinate system, a positive x-axis extends towardthe heel portion from the origin, a positive y-axis extends rearwardlyfrom the origin, and a positive z-axis extends upwardly from the origin.The body includes a central region in which −25 mm<x<25 mm. The soleportion that is contained within the central region includes a forwardsole region located adjacent to the face portion and a sole bar locatedrearward of the forward sole region, with the forward sole regiondefining a wall having a minimum forward sole thickness T_(FS) and thesole bar defining a body having a maximum sole bar thickness T_(SB),such that 0.05<T_(FS)/T_(SB)<0.4. The sole portion includes a slotextending in a substantially heel-to-toe direction of the sole portion,the slot defining a portion of a path that extends through the soleportion and into the rear void.

In some embodiments, the slot has a slot length comprising the distancebetween a part of the slot nearest the toe portion and a part of theslot nearest the heel region, with the slot length being from about 15mm to about 85 mm.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm.

In some embodiments, the slot has a slot length L1, the body has a solelength L_(B), and a ratio of the slot length to the sole lengthsatisfies the following inequality: 0.35<L1/L_(B)<0.67.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.

In some embodiments, a filler material is located in the slot.

In some embodiments, the face portion defines a face plane and the pathincludes a lower path portion having a length of at least 1 mm anddefining a lower path angle that is within 30° of being parallel withsaid face plane, an intermediate path portion having a length of atleast 1 mm and defining an intermediate path angle that is within 30° ofbeing perpendicular to said face plane, and an upper path portion havinga length of at least 1 mm and defining an upper path angle that iswithin 30° of being parallel with said face plane.

In a seventh aspect, a clubhead for an iron-type golf club includes abody having a heel portion, a sole portion, a toe portion, a top-lineportion, and a face portion, wherein said sole portion extendsrearwardly from a lower end of said face portion, the body furtherdefining a rear void. The face portion includes an ideal strikinglocation that defines the origin of a coordinate system in which anx-axis is tangential to the face portion at the ideal striking locationand is parallel to a ground plane when the body is in a normal addressposition, a y-axis extends perpendicular to the x-axis and is alsoparallel to the ground plane, and a z-axis extends perpendicular to theground plane. In the coordinate system, a positive x-axis extends towardthe heel portion from the origin, a positive y-axis extends rearwardlyfrom the origin, and a positive z-axis extends upwardly from the origin.The body includes a central region in which −25 mm<x<25 mm. The soleportion that is contained within the central region includes a forwardsole region located adjacent to the face portion and a sole bar locatedrearward of the forward sole region, with the forward sole regiondefining a wall having a minimum forward sole thickness T_(FS) and thesole bar defining a body having a maximum sole bar thickness T_(SB). Thesole portion includes a slot extending in a substantially heel-to-toedirection of the sole portion, the slot defining a portion of a paththat extends through the sole portion and into the rear void, with thepath including a lower path portion having a length of at least 1 mm anddefining a lower path angle that is within 30° of being parallel withsaid face plane, an intermediate path portion having a length of atleast 1 mm and defining an intermediate path angle that is within 30° ofbeing perpendicular to said face plane, and an upper path portion havinga length of at least 1 mm and defining an upper path angle that iswithin 30° of being parallel with said face plane.

In some embodiments, the slot has a slot length comprising the distancebetween a part of the slot nearest the toe portion and a part of theslot nearest the heel region, with the slot length being from about 15mm to about 85 mm.

In some embodiments, 0.8 mm<T_(FS)<3.0 mm.

In some embodiments, the slot has a slot length L1, the body has a solelength L_(B), and a ratio of the slot length to the sole lengthsatisfies the following inequality: 0.35<L1/L_(B)<0.67.

In some embodiments, the body defines an interior cavity, and the bodyhas a volume V that satisfies the following inequality: 10 cc<V<120 cc.

In some embodiments, a filler material is located in the slot.

The foregoing and other features and advantages of the golf club headsdescribed herein will become more apparent from the following detaileddescription, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example and notlimitation in the figures of the accompanying drawings in which likereferences indicate similar elements.

FIG. 1A is a front view of an embodiment of a golf club head.

FIG. 1B is an elevated toe perspective view of a golf club head.

FIG. 1C is a cross-sectional view taken along section lines 1B-1B inFIG. 1A, showing an embodiment of a hollow club head.

FIG. 1D is a cross-sectional view taken along section lines 1B-1B inFIG. 1A, showing an embodiment of a cavity back club head.

FIG. 1E is a cross-sectional view taken along section lines 1B-1B inFIG. 1A, showing another embodiment of a hollow club head.

FIG. 1F is a cross-sectional view showing a portion of the embodiment ofthe hollow club head shown in FIG. 1E.

FIG. 2A is a bottom perspective view of an embodiment of a golf clubhead.

FIG. 2B is a bottom view of the sole of the golf club head shown in FIG.2A.

FIG. 2C is a cross-sectional view of the golf club head shown in FIG.2A.

FIGS. 2D-E are schematic representations of a profile of the outersurface of a portion of a club head that surrounds and includes theregion of a channel.

FIGS. 2F-H are cross-sectional views of a channel region of anembodiment of a golf club head.

FIGS. 3A-3B, 4A-4B, and 5A-5B, are cross-sectional views of exemplarygolf club heads.

FIGS. 6A-B are bottom views of the soles of exemplary golf club heads.

FIGS. 7A-7B, 8A-8B, and 9 are cross-sectional views of exemplary golfclub heads.

FIG. 10A is a bottom view of the sole of and exemplary golf club head.

FIG. 10B is a cross-sectional view of the golf club head shown in FIG.10A.

FIGS. 11A-J are bottom views of the soles of exemplary golf club heads.

FIGS. 12A-C are elevated toe perspective views of exemplary golf clubheads.

FIG. 13 is a front view of an exemplary golf club head including aschematic representation of the projections of a pair of channels on thestriking face.

FIGS. 14A-C are front views of additional exemplary golf club headsincluding schematic representations of the projections of a channel onthe striking face.

FIGS. 15A-C are cross-sectional views of exemplary golf club heads.

FIG. 16 is an illustration of an embodiment of a golf club set.

FIG. 17A is a cross-sectional view of another embodiment of a golf clubhead.

FIG. 17B is a close-up cross-sectional view of a portion of the golfclub head shown in FIG. 17A.

FIGS. 18A-B are cross-sectional views of two embodiments of golf clubheads taken along section line 18-18 in FIG. 17B.

FIG. 18C is a close-up view of a cutout or window of the golf club headshown in FIG. 18A.

FIG. 19A is a cross-sectional view of another embodiment of a golf clubhead.

FIG. 19B is a close-up cross-sectional view of a portion of the golfclub head shown in FIG. 19A.

FIG. 19C is a close-up cross-sectional view of a golf club head having aslot including a filler material.

FIG. 20A is a cross-sectional view of another embodiment of a golf clubhead.

FIG. 20B is a close-up cross-sectional view of a portion of the golfclub head shown in FIG. 20A.

DETAILED DESCRIPTION

Various embodiments and aspects of the inventions will be described withreference to details discussed below, and the accompanying drawings willillustrate the various embodiments. The following description anddrawings are illustrative of the invention and are not to be construedas limiting the invention. Numerous specific details are described toprovide a thorough understanding of various embodiments of the presentinvention. However, in certain instances, well-known or conventionaldetails are not described in order to provide a concise discussion ofembodiments of the present inventions.

As used herein, the terms “coefficient of restitution,” “COR,” “relativecoefficient of restitution,” “relative COR,” “characteristic time,” and“CT” are defined according to the following. The coefficient ofrestitution (COR) of an iron clubhead is measured according toprocedures described by the USGA Rules of Golf as specified in the“Interim Procedure for Measuring the Coefficient of Restitution of anIron Clubhead Relative to a Baseline Plate,” Revision 1.2, Nov. 30, 2005(hereinafter “the USGA COR Procedure”). Specifically, a COR value for abaseline calibration plate is first determined, then a COR value for aniron clubhead is determined using golf balls from the same dozen(s) usedin the baseline plate calibration. The measured calibration plate CORvalue is then subtracted from the measured iron clubhead COR to obtainthe “relative COR” of the iron clubhead.

To illustrate by way of an example: following the USGA COR Procedure, agiven set of golf balls may produce a measured COR value for a baselinecalibration plate of 0.845. Using the same set of golf balls, an ironclubhead may produce a measured COR value of 0.825. In this example, therelative COR for the iron clubhead is 0.825 0.845=−0.020. This ironclubhead has a COR that is 0.020 lower than the COR of the baselinecalibration plate, or a relative COR of −0.020.

The characteristic time (CT) is the contact time between a metal massattached to a pendulum that strikes the face center of the golf clubhead at a low speed under conditions prescribed by the USGA clubconformance standards.

As used herein, the term “volume” when used to refer to a golf clubheadrefers to a clubhead volume measured according to the proceduredescribed in Section 5.0 of the “Procedure For Measuring the ClubheadSize of Wood Clubs,” Revision 1.0.0, published Nov. 21, 2003 by theUnited States Golf Association (the USGA) and R&A Rules Limited. Theforegoing procedure includes submerging a clubhead in a large volumecontainer of water. In the case of a volume measurement of a hollow irontype clubhead, any holes or openings in the walls of the clubhead are tobe covered or otherwise sealed prior to lowering the clubhead into thewater.

1. Iron Type Golf Club Heads

FIG. 1A illustrates an iron type golf club head 100 including a body 113having a heel 102, a toe 104, a sole portion 108, a top line portion106, and a hosel 114. The golf club head 100 is shown in FIG. 1A in anormal address position with the sole portion 108 resting upon a groundplane 111, which is assumed to be perfectly flat. As used herein,“normal address position” means the club head position wherein a vectornormal to the center of the club face substantially lies in a firstvertical plane (i.e., a vertical plane is perpendicular to the groundplane 111), a centerline axis 115 of the hosel 114 substantially lies ina second vertical plane, and the first vertical plane and the secondvertical plane substantially perpendicularly intersect. The center ofthe club face is determined using the procedures described in the USGA“Procedure for Measuring the Flexibility of a Golf Clubhead,” Revision2.0, Mar. 25, 2005.

A lower tangent point 190 on the outer surface of the club head 100 of aline 191 forming a 45° angle relative to the ground plane 111 defines ademarcation boundary between the sole portion 108 and the toe 104.Similarly, an upper tangent point 192 on the outer surface of the clubhead 100 of a line 193 forming a 45° angle relative to the ground plane111 defines a demarcation boundary between the top line portion 106 andthe toe 104. In other words, the portion of the club head that is aboveand to the left (as viewed in FIG. 1A) of the lower tangent point 190and below and to the left (as viewed in FIG. 1A) of the upper tangentpoint 192 is the toe portion 104.

In certain embodiments such as that shown in FIGS. 1C, 1D, and 1E, thestriking face 110 may vary in thickness and have a minimum facethickness and a maximum face thickness. In certain embodiments, theminimum face thickness may be between about 1.5 mm and about 2.5 mm,with a preferred thickness of about 2 mm or less. The maximum facethickness may be between about 1.7 mm and about 2.5 mm or less thanabout 2.7 mm. In some embodiments the minimum face may be within a rangeof about 1.0 mm-3.0 mm, preferably 1.5-2.5 mm, and also preferably in arange of about 1.6-2.0 mm.

The striking face 110 defines a face plane 125 and includes grooves 112that are designed for impact with the golf ball. In some embodiments,the golf club head 100 can be a single unitary cast piece, while inother embodiments, a striking plate can be formed separately to beadhesively or mechanically attached to the body 113 of the golf clubhead 100.

FIGS. 1A and 1B also show an ideal striking location 101 on the strikingface 110 and respective orthogonal CG axes. As used herein, the idealstriking location 101 is located within the face plane 125 and coincideswith the location of the center of gravity (CG) of the golf club headalong the CG x-axis 105 (i.e., CG-x) and is offset from the leading edge142 (defined as the midpoint of a radius connecting the sole portion 108and the face plane 125) by a distance d of 16.5 mm within the face plane125, as shown in FIG. 1B. A CG x-axis 105, CG y-axis 107, and CG z-axis103 intersect at the ideal striking location 101, which defines theorigin of the orthogonal CG axes. With the golf club head 100 in thenormal address position, the CG x-axis 105 is parallel to the groundplane 111 and is oriented perpendicular to a normal extending from thestriking face 110 at the ideal striking location 101. The CG y-axis 107is also parallel to the ground plane and is perpendicular to the CGx-axis 105. The CG z-axis 103 is oriented perpendicular to the groundplane. In addition, a CG z-up axis 109 is defined as an axisperpendicular to the ground plane 111 and having an origin at the groundplane 111.

In certain embodiments, a desirable CG-y location is between about 0.25mm to about 20 mm along the CG y-axis 107 toward the rear portion of theclub head. Additionally, a desirable CG-z location is between about 12mm to about 25 mm along the CG z-up axis 109, as previously described.

The golf club head may be of solid (i.e., “blades” and “musclebacks”),hollow, cavity back, or other construction. FIG. 1C shows a crosssectional side view along the cross-section lines 1C-1C shown in FIG. 1Aof an embodiment of the golf club head having a hollow construction.FIG. 1D shows a cross sectional side view along the cross-section lines1D-1D of an embodiment of a golf club head having a cavity backconstruction. The cross-section lines 1C, 1D-1C, 1D are taken throughthe ideal striking location 101 on the striking face 110. The strikingface 110 includes a front surface 110 a and a rear surface 110 b. Boththe hollow iron golf club head and cavity back iron golf club headembodiments further includes a back portion 128 and a front portion 130.

In the embodiments shown in FIGS. 1A-1D, the grooves 112 are located onthe striking face 110 such that they are centered along the CG x-axisabout the ideal striking location 101, i.e., such that the idealstriking location 101 is located within the striking face plane 125 onan imaginary line that is both perpendicular to and that passes throughthe midpoint of the longest score-line groove 112. In other embodiments(not shown in the drawings), the grooves 112 may be shifted along the CGx-axis to the toe side or the heel side relative to the ideal strikinglocation 101, the grooves 112 may be aligned along an axis that is notparallel to the ground plane 111, the grooves 112 may havediscontinuities along their lengths, or the grooves may not be presentat all. Still other shapes, alignments, and/or orientations of grooves112 on the surface of the striking face 110 are also possible.

In reference to FIG. 1A, the clubhead 100 has a sole length, L_(B), anda clubhead height, H_(CH). The sole length, L_(B), is defined as thedistance between two points projected onto the ground plane 111. A heelside 116 of the sole is defined as the intersection of a projection ofthe hosel axis 115 onto the ground plane 111. A toe side 117 of the soleis defined as the intersection point of the vertical projection of thelower tangent point 190 (described above) onto the ground plane 111. Thedistance between the heel side 116 and toe side 117 of the sole is thesole length L_(B) of the clubhead. The clubhead height, H_(CH), isdefined as the distance between the ground plane 111 and the uppermostpoint of the clubhead as projected in the x-z plane, as illustrated inFIG. 1A. FIG. 1B illustrates an elevated toe view of the golf club head100 including a back portion 128, a front portion 130, a sole portion108, a top line portion 106, and a striking face 110, as previouslydescribed. A leading edge 142 is defined by the midpoint of a radiusconnecting the face plane 125 and the sole portion 108. The clubheadincludes a clubhead front-to-back depth, D_(CH), which is the distancebetween two points projected onto the ground plane 111. A forward end118 of the clubhead is defined as the intersection of the projection ofthe leading edge 142 onto the ground plane 111. A rearward end 119 ofthe clubhead is defined as the intersection of the projection of therearward-most point of the clubhead (as viewed in the y-z plane) ontothe ground plane 111. The distance between the forward end 118 andrearward end 119 of the clubhead is the clubhead depth Dal.

In certain embodiments of iron type golf club heads having hollowconstruction, such as the embodiment shown in FIG. 1C, a recess 134 islocated above the rear protrusion 138 in the back portion 128 of theclub head. A back wall 132 encloses the entire back portion 128 of theclub head to define an interior cavity 120. The interior cavity 120 maybe completely or partially hollow, or it optionally may be filled with afiller material. In the embodiment shown in FIG. 1C, the interior cavity120 includes a vibration dampening plug 121 that is retained between therear surface 110 b of the striking face and the inner surface 132 b ofthe back wall. Suitable filler materials and details relating to thenature and materials comprising the plug 121 are described in US PatentApplication Publication No. 2011/0028240, which is incorporated hereinby reference.

FIG. 1C further shows an optional ridge 136 extending across a portionof the outer back wall surface 132 a forming an upper concavity and alower concavity. An inner back wall surface 132 b defines a portion ofthe cavity 120 and forms a thickness between the outer back wall surface132 a and the inner back wall surface 132 b. In some embodiments, theback wall thickness varies between a thickness of about 0.5 mm to about4 mm. A sole bar 135 is located in a low, rearward portion of theclubhead 100. The sole bar 135 has a relatively large thickness inrelation to the striking plate and other portions of the clubhead 100,thereby accounting for a significant portion of the mass of the clubhead100, and thereby shifting the center of gravity (CG) of the clubhead 100relatively lower and rearward. A channel 150 described more fully belowis formed in the sole bar 135. Furthermore, the sole portion 108 has aforward portion 144 that is located immediately rearward of the strikingface 110. In the embodiment shown in FIG. 1C, the forward portion 144 ofthe sole is a relatively thin-walled section of the sole that extendswithin a region between the channel 150 and the striking face 110.

FIG. 1D further shows a sole bar 135 of the cavity back golf club head100. The sole bar 135 has a relatively large thickness in relation tothe striking plate and other portions of the golf club head 100, therebyaccounting for a significant portion of the mass of the golf club head100, and thereby shifting the center of gravity (CG) of the golf clubhead 100 relatively lower and rearward. The embodiment shown in FIG. 1Dalso includes a forward portion 144 of the sole that has a reduced solethickness and that extends within between the sole bar 135 and thestriking face 110. A channel 150 described more fully below is locatedin a forward region of the sole bar 135. FIG. 1E shows anotherembodiment of a hollow iron clubhead 100 having a channel 150. As withthe embodiment shown in FIG. 1C, the clubhead 100 includes a strikingface 110, a top line 106, a sole 108, and a back wall 132. The soleincludes a sole bar 135 having a channel 150 defined by a forward wall152 and rear wall 154. A forward portion 144 of the sole is locatedbetween the striking face 110 and the forward wall 152 of the slot. Thehollow clubhead 100 includes an aperture 133 that is suitable forinstalling a vibration dampening plug 121 like that shown in FIG. 1C,and which is described in more detail in US Patent ApplicationPublication No. 2011/0028240, which is incorporated by reference.Installation of the vibration dampening plug 121 effectively seals theaperture 133.

In some embodiments, the volume of the hollow iron clubhead 100 may bebetween about 10 cubic centimeters (cc) and about 120 cc. For example,in some embodiments, the hollow iron clubhead 100 may have a volumebetween about 20 cc and about 110 cc, such as between about 30 cc andabout 100 cc, such as between about 40 cc and about 90 cc, such asbetween about 50 cc and about 80 cc, such as between about 60 cc andabout 80 cc. In addition, in some embodiments, the hollow iron clubhead100 has a clubhead depth, D_(CH), that is between about 15 mm and about100 mm. For example, in some embodiments, the hollow iron clubhead 100may have a clubhead depth, D_(CH), of between about 20 mm and about 90mm, such as between about 30 mm and about 80 mm, such as between about40 mm and about 70 mm.

In certain embodiments of the golf club head 100 that include a separatestriking plate attached to the body 113 of the golf club head, thestriking plate can be formed of forged maraging steel, maragingstainless steel, or precipitation-hardened (PH) stainless steel. Ingeneral, maraging steels have high strength, toughness, andmalleability. Being low in carbon, they derive their strength fromprecipitation of inter-metallic substances other than carbon. Theprinciple alloying element is nickel (15% to nearly 30%). Other alloyingelements producing inter-metallic precipitates in these steels includecobalt, molybdenum, and titanium. In one embodiment, the maraging steelcontains 18% nickel. Maraging stainless steels have less nickel thanmaraging steels but include significant chromium to inhibit rust. Thechromium augments hardenability despite the reduced nickel content,which ensures the steel can transform to martensite when appropriatelyheat-treated. In another embodiment, a maraging stainless steel C455 isutilized as the striking plate. In other embodiments, the striking plateis a precipitation hardened stainless steel such as 17-4, 15-5, or 17-7.

The striking plate can be forged by hot press forging using any of thedescribed materials in a progressive series of dies. After forging, thestriking plate is subjected to heat-treatment. For example, 17-4 PHstainless steel forgings are heat treated by 1040° C. for 90 minutes andthen solution quenched. In another example, C455 or C450 stainless steelforgings are solution heat-treated at 830° C. for 90 minutes and thenquenched.

In some embodiments, the body 113 of the golf club head is made from17-4 steel. However another material such as carbon steel (e.g., 1020,1030, 8620, or 1040 carbon steel), chrome-molybdenum steel (e.g., 4140Cr—Mo steel), Ni—Cr—Mo steel (e.g., 8620 Ni—Cr—Mo steel), austeniticstainless steel (e.g., 304, N50, or N60 stainless steel (e.g., 410stainless steel) can be used.

In addition to those noted above, some examples of metals and metalalloys that can be used to form the components of the parts describedinclude, without limitation: titanium alloys (e.g., 3-2.5, 6-4, SP700,15-3-3-3, 10-2-3, or other alpha/near alpha, alpha-beta, and beta/nearbeta titanium alloys), aluminum/aluminum alloys (e.g., 3000 seriesalloys, 5000 series alloys, 6000 series alloys, such as 6061-T6, and7000 series alloys, such as 7075), magnesium alloys, copper alloys, andnickel alloys.

In still other embodiments, the body 113 and/or striking plate of thegolf club head are made from fiber-reinforced polymeric compositematerials, and are not required to be homogeneous. Examples of compositematerials and golf club components comprising composite materials aredescribed in U.S. Patent Application Publication No. 2011/0275451, whichis incorporated herein by reference in its entirety.

The body 113 of the golf club head can include various features such asweighting elements, cartridges, and/or inserts or applied bodies as usedfor CG placement, vibration control or damping, or acoustic control ordamping. For example, U.S. Pat. No. 6,811,496, incorporated herein byreference in its entirety, discloses the attachment of mass alteringpins or cartridge weighting elements.

After forming the striking plate and the body 113 of the golf club head,the striking plate and body portion 113 contact surfaces can befinish-machined to ensure a good interface contact surface is providedprior to welding. In some embodiments, the contact surfaces are planarfor ease of finish machining and engagement.

2. Iron Type Golf Club Heads Having a Flexible Boundary Structure

In some embodiments of the iron type golf club heads described herein, aflexible boundary structure (“FBS”) is provided at one or more locationson the club head. The flexible boundary structure may comprise, inseveral embodiments, a slot, a channel, a gap, a thinned or weakenedregion, or other structure that enhances the capability of an adjacentor related portion of the golf club head to flex or deflect and tothereby provide a desired improvement in the performance of the golfclub head. For example, in several embodiments, the flexible boundarystructure is located proximate the striking face of the golf club headin order to enhance the deflection of the striking face upon impact witha golf ball during a golf swing. The enhanced deflection of the strikingface may result, for example, in an increase in the coefficient ofrestitution (“COR”) of the golf club head. In other embodiments, theincreased perimeter flexibility of the striking face may cause thestriking face to deflect in a different location and/or different mannerin comparison to the deflection that occurs upon striking a golf ball inthe absence of the channel, slot, or other flexible boundary structure.

Turning to FIGS. 2A-2C, an embodiment of a cavity back golf club head200 having a flexible boundary structure is shown. In the embodiment,the flexible boundary structure is a channel 250 that is located on thesole of the club head. It should be noted that, as described above, theflexible boundary structure may comprise a slot, a channel, a gap, athinned or weakened region, or other structure. For clarity, however,the descriptions herein will be limited to embodiments containing achannel, such as the channel 250 illustrated in FIGS. 2A-C, or a slot,included in several embodiments described below, with it beingunderstood that other flexible boundary structures may be used toachieve the benefits described herein.

The channel 250 extends over a region of the sole 208 generally parallelto and spaced rearwardly from the striking face plane 225. The channelextends into and is defined by a forward portion of the sole bar 235,defining a forward wall 252, a rear wall 254, and an upper wall 256. Achannel opening 258 is defined on the sole portion 208 of the club head.The forward wall 252 further defines, in part, a first hinge region 260located at the transition from the forward portion of the sole 244 tothe forward wall 252, and a second hinge region 262 located at atransition from the upper region of the forward wall 252 to the sole bar235. The first hinge region 260 and second hinge region 262 are portionsof the golf club head that contribute to the increased deflection of thestriking face 210 of the golf club head due to the presence of thechannel 250. In particular, the shape, size, and orientation of thefirst hinge region 260 and second hinge region 262 are designed to allowthese regions of the golf club head to flex under the load of a golfball impact. The flexing of the first hinge region 260 and second hingeregion 262, in turn, creates additional deflection of the striking face210.

Several aspects of the size, shape, and orientation of the club head 200and channel 250 are illustrated in the embodiment shown in FIGS. 2A-H.For example, for each cross-section of the clubhead defined within they-z plane, the face to channel distance D1 is the distance measured onthe ground plane 211 between a face plane projection point 226 and achannel centerline projection point 227. (See FIG. 2F). The face planeprojection point 226 is defined as the intersection of a projection ofthe striking face plane 225 onto the ground plane 211. The channelcenterline projection point 227 is defined as the intersection of aprojection of a channel centerline 229 onto the ground plane 211. Thechannel centerline 229 is determined according to the following.

Referring to FIGS. 2D-E, a schematic profile 249 of the outer surface ofa portion of the clubhead 200 that surrounds and includes the region ofthe channel 250 is shown. The schematic profile has an interior side 249a and an exterior side 249 b. A forward sole exterior surface 208 aextends on a forward side of the channel 250, and a rearward soleexterior surface 208 b extends on a rearward side of the channel 250.The channel has a forward wall exterior surface 252 a, a rear wallexterior surface 254 a, and an upper wall exterior surface 256 a. Aforward channel entry point 264 is defined as the midpoint of a curvehaving a local minimum radius (r_(min), measured from the interior side249 a of the schematic profile 249) that is located between the forwardsole exterior surface 208 a and the forward wall exterior surface 252 a.A rear channel entry point 265 is defined as the midpoint of a curvehaving a local minimum radius (r_(min), also measured from the interiorside 249 a of the schematic profile 249) that is located between therearward sole exterior surface 208 b and the rear wall exterior surface254 a. An imaginary line 266 that connects the forward channel entrypoint 264 and the rear channel entry point 265 defines the channelopening 258. A midpoint 266 a of the imaginary line 266 is one of twopoints that define the channel centerline 229. The other point definingthe channel centerline 229 is an upper channel peak 267, which isdefined as the midpoint of a curve having a local minimum radius(r_(min), as measured from the exterior side 249 b of the schematicprofile 249) that is located between the forward wall exterior surface252 a and the rear wall exterior surface 254 a. In an embodiment havingone or more flat segment(s) or flat surface(s) located at the upper endof the channel between the forward wall 252 and rear wall 254, the upperchannel peak 267 is defined as the midpoint of the flat segment(s) orflat surface(s).

Another aspect of the size, shape, and orientation of the club head 200and channel 250 is the sole width. For example, for each cross-sectionof the clubhead defined within the y-z plane, the sole width, D3, is thedistance measured on the ground plane 211 between the face planeprojection point 226 and a trailing edge projection point 246. (See FIG.2F). The face plane projection point 226 is defined above. The trailingedge projection point 246 is the intersection with the ground plane 211of an imaginary vertical line passing through the trailing edge 245 ofthe clubhead 200. The trailing edge 245 is defined as a midpoint of aradius or a point that constitutes a transition from the sole portion208 to the back wall 232 or other structure on the back portion 228 ofthe clubhead.

Still another aspect of the size, shape, and orientation of the clubhead 200 and channel 250 is the channel to rear distance, D2. Forexample, for each cross-section of the clubhead defined within the y-zplane, the channel to rear distance D2 is the distance measured on theground plane 211 between the channel centerline projection point 227 anda vertical projection of the trailing edge 245 onto the ground plane211. (See FIG. 2F). As a result, for each such cross-section, D1+D2=D3.

FIGS. 3A-B illustrate two embodiments of golf club heads 300 having achannel 350 that operates as a flexible boundary structure. The twoembodiments are similarly designed with the exception of the face tochannel distance D1 of each embodiment, as measured at a cross-sectiontaken at the ideal striking location 301. The club head embodiment shownin FIG. 3A includes a face to channel distance D1 that is substantiallylarger than the face to channel distance D1 of the embodiment shown inFIG. 3B while the sole width D3 (as measured at the same cross-sectiontaken at the ideal striking location 301) of each of the embodiments isthe same.

Table 1 below lists several exemplary values for the face to channeldistance D1, channel to rear distance D2, sole width D3, and the ratiosof D1/D3, D2/D3, and D1/D2 for several examples of clubheads thatinclude a channel 350 according to the embodiments described herein. Themeasurements reported in Table 1 are for the average face to channeldistance (D1), average channel to rear distance (D2), and average solewidth (D3) over a portion of the clubhead extending 25 mm to each side(i.e., toe side and heel side) of the ideal striking location 301. Asused herein, the terms “average face to channel distance (D1),” “averagechannel to rear distance (D2),” and “average sole width (D3)” refer toan average of a plurality of D1, D2, or D3 measurements, with theplurality of D1, D2, or D3 measurements being taken within a pluralityof imaginary parallel vertical planes that include a first verticalplane passing through the ideal striking location 301 and that containsa vector drawn normal to the striking face 310 at the ideal strikinglocation 301, and a plurality of additional vertical planes that areparallel to the first vertical plane and that are spaced at regular 1 mmincrements on each side of the ideal striking location 301.

TABLE 1 Loft D1 (mm) D2 (mm) D3 (mm) D1/D3 D2/D3 D1/D2 Ex. 1 20-21°3.5-17 11-24 15-28 0.13-0.61 0.39-0.86 0.15-0.71 5.5-14 13-22 16-270.20-0.52 0.48-0.81 0.25-0.64  8-11 15-18 17-26 0.31-0.42 0.58-0.690.44-0.61 Ex. 2 26-28° 3.5-17 11-24 15-28 0.13-0.61 0.39-0.86 0.15-0.715.5-14 13-22 16-27 0.20-0.52 0.48-0.81 0.25-0.64  8-11 15-18 17-260.32-0.43 0.58-0.69 0.44-0.61

Returning to FIGS. 2A-C, additional aspects of the design of the clubhead 200 and channel 250 include the channel width W1, channel lengthL1, and channel depth H1. The channel width W1 is a measure of thedistance in a horizontal plane (i.e., a plane that is parallel to theground plane 211) between the forward wall 252 and rear wall 254 of thechannel at a given cross-section of the channel 250. The channel lengthL1 is generally a measure of the distance on the sole 208 of the clubhead between the toeward-most point of the channel and the heelward-mostpoint of the channel, without taking into account any curvature of thechannel 250. The channel depth H1 is generally a measure of the distancefrom the ground plane 211 to the highest point (in the y-z plane) of theinner surface of the channel on the channel upper wall 256 when theclubhead 200 is resting on the ground plane 211. As shown in FIGS. 2A-C,in some embodiments, the channel 250 includes a constant width W1 andconstant depth H1 over its full length. In other embodiments, one ormore of these three parameters may be varied to achieve desired designand/or performance objectives.

FIGS. 4A-B illustrate two embodiments of golf club heads 400 having achannel 450 that operates as a flexible boundary structure. The twoembodiments are similarly designed with the exception of the channelwidth W1 of each embodiment. The club head embodiment shown in FIG. 4Aincludes a channel width W1 that is constant, and that is substantiallysmaller than the (also constant) channel width W1 of the embodimentshown in FIG. 4B. In other embodiments, a channel may have a width W1that is not constant. In those embodiments, an average channel width W1may be determined. As used herein, the term “average channel width W1”refers to an average of a plurality of W1 measurements, with theplurality of W1 measurements being taken within a plurality of imaginaryparallel horizontal planes that include a first horizontal plane passingthrough a point that is located at a distance equal to one-half of thechannel height H1 above the ground plane 411, and a plurality ofadditional horizontal planes that are parallel to the first horizontalplane and that are spaced at regular 0.5 mm increments above and belowthe first horizontal plane. The uppermost imaginary parallel horizontalplane is located at a height that is 80% of the channel height H1 abovethe ground plane 411, and the lowermost imaginary parallel horizontalplane is located at a height that is at least 20% of the channel heightH1 above the ground plane 411. All of the imaginary parallel horizontalplanes must include a point located on the forward wall 452 of thechannel and the rear wall 454 of the channel. In some embodiments of theclub heads described herein, the average channel width W1 may be fromabout 0.50 mm to about 10.0 mm, such as from about 1.0 mm to about 4.0mm, such as from about 1.25 mm to about 2.5 mm. In one embodiment, theaverage channel width W1 is about 1.75 mm.

In some embodiments, the channel width W1 at the channel opening 258 issufficiently wide that the forward wall 252 and rear wall 254 of thechannel do not contact one another when, for example, a golf ball isstruck by the clubhead 200, but the channel width W1 at the channelopening 258 is sufficiently narrow that the amount of dirt, grass, andother materials entering the channel 250 may be reduced relative to achannel having a wider channel opening 258. For example, in someembodiments, the channel width W1 at the channel opening 258 may be fromabout 0.5 mm to about 5 mm, such as from about 1.0 mm to about 4 mm,such as from about 1.25 mm to about 3 mm.

FIGS. 5A-B illustrate two embodiments of golf club heads 500 having achannel 550 that operates as a flexible boundary structure. The twoembodiments are similarly designed with the exception of the channeldepth H1 of each embodiment.

The club head embodiment shown in FIG. 5A includes a constant channeldepth H1 that is substantially smaller than the (also constant) channeldepth H1 of the embodiment shown in FIG. 5B. In other embodiments, achannel may have a depth H1 that is not constant. In those embodiments,a maximum channel depth H1_(MAX) and an average channel depth H1_(AVG)may be determined. As used herein, the term “maximum channel depthH1_(MAX)” refers to a maximum value for the channel depth H1 occurringover the full length of the channel. As used herein, the term “averagechannel depth H1_(AVG)” refers to an average of H1 measurements, withthe plurality of H1 measurements being taken within a plurality ofimaginary parallel vertical planes that include a first vertical planepassing through the ideal striking location 501 and that contains avector drawn normal to the striking face 510 at the ideal strikinglocation 501, and a plurality of additional vertical planes that areparallel to the first vertical plane and that are spaced at regular 1 mmincrements on each side of the ideal striking location 501.

Table 2 below lists several exemplary values for the average channeldepth H1_(AVG), maximum channel depth H1_(MAX), club head height H_(CH),and the ratios of H1_(AVG)/H_(CH) and H1_(MAX)/H_(CH) for severalexamples of clubheads that include a channel according to theembodiments described herein.

TABLE 2 H1_(AVG) H1_(MAX) H_(CH) Loft (mm) (mm) (mm) H1_(AVG)/H_(CH)H1_(MAX)/H_(CH) Ex. 1 20-21° 5.0-25.0 5.0-45 25-75 0.07-0.50 0.07-0.70(4I) 6.0-14.5 6.0-30 35-65 0.10-0.41 0.10-0.60 8.5-13.0 8.5-23 40-600.14-0.33 0.14-0.50 Ex. 2 26-28° 5.0-25.0 5.0-45 25-75 0.07-0.500.07-0.70 (6I) 6.0-14.5 6.0-30 35-65 0.10-0.41 0.10-0.60 8.5-13.0 8.5-2340-60 0.14-0.33 0.14-0.50

FIGS. 6A-B illustrate two embodiments of golf club heads 600 having achannel 650 that operates as a flexible boundary structure. The twoembodiments are similarly designed with the exception of the channellength L1 of each embodiment. The club head embodiment shown in FIG. 6Aincludes a channel length L1 that is substantially shorter than thechannel length L1 of the embodiment shown in FIG. 6B. In someembodiments of the club heads described herein, the channel length L1may be from about 15 mm to about 62 mm, such as from about 40 mm toabout 57 mm, such as from about 45 mm to about 55 mm. In one embodiment,the channel length L1 is about 50 mm.

Table 3 below lists several exemplary values for the channel length L1,sole length L_(B), and the ratio of L1/L_(B) for several examples ofclubheads that include a channel according to the embodiments describedherein.

TABLE 3 Loft L1 (mm) L_(B) (mm) L1/L_(B) Ex. 1 20-21° 15-85 mm 65-90 mm0.17-1.0  (4I) 30-57 mm 70-85 mm 0.35-0.67 45-55 mm 75-82 mm 0.55-0.65Ex. 2 26-28° 15-62 mm 65-90 mm 0.17-1.0  (6I) 30-57 mm 70-85 mm0.35-0.67 45-55 mm 75-82 mm 0.55-0.65

Table 4 below lists several exemplary values for the channel length L1,the average channel depth H1 AVG, the maximum channel depth H1_(MAX),and the ratios of H1_(AVG)/L1 and H1_(MAX)/L1 for several examples ofclubheads that include a channel according to the embodiments describedherein.

TABLE 4 H1_(AVG) H1_(MAX) Loft (mm) (mm) L1 (mm) H1_(AVG)/L1 H1_(MAX)/L1Ex. 1 20-21° 5.0-25.0 5.0-45 15-85 mm 0.06-0.50 0.06-0.65 (4I) 6.0-14.56.0-30 30-57 mm 0.11-0.40 0.11-0.50 8.5-13.0 8.5-23 45-55 mm 0.18-0.300.18-0.40 Ex. 2 26-28° 5.0-25.0 5.0-45 15-62 mm 0.06-0.50 0.06-0.65 (6I)6.0-14.5 6.0-30 30-57 mm 0.11-0.40 0.11-0.50 8.5-13.0 8.5-23 45-55 mm0.18-0.30 0.18-0.40

Returning to FIGS. 2A-H, and specifically to FIG. 2G, still otheraspects of the design of the club head 200 and channel 250 include thewall and component thicknesses of at least the following three portionsof the club head. A first wall thickness, T1, is a measure of thethickness of the first hinge region 260. A second wall thickness, T2, isa measure of the thickness of the second hinge region 262. A forwardsole wall minimum thickness, T_(FS), is a measure of the minimumthickness (measured in a vertical plane) of the forward portion 244 ofthe sole, i.e., the portion of the sole 208 located between the strikingface 210 and the channel 250. A sole bar maximum thickness T_(SB) is ameasure of the maximum thickness (measured in a vertical plane) of theportion of the sole bar 235 located rearward of the channel 250. Asshown in FIGS. 2A-C, in some embodiments, the club head 200 includes afirst hinge region 260, second hinge region 262, and forward portion 244of the sole that each have a constant thickness over their full lengths.In other embodiments, one or more of these parameters may be varied toachieve desired design and/or performance objectives.

FIGS. 7A-B illustrate two embodiments of golf club heads 700 having achannel 750 that operates as a flexible boundary structure. The twoembodiments are similarly designed with the exception of the orientationof the channel 750 and the resultant variation in the thickness, T1, ofthe first hinge region of each embodiment. The club head embodimentshown in FIG. 7A includes a first hinge region thickness T1 that issubstantially smaller/thinner than the first hinge region thickness T1of the embodiment shown in FIG. 7B. In some embodiments of the clubheads described herein, the first hinge region thickness T1 may be fromabout 0.5 mm to about 5.0 mm, such as from about 1.0 mm to about 3.0 mm,such as from about 1.2 mm to about 2.0 mm. In one embodiment, the firsthinge region thickness T1 is about 1.5 mm.

FIGS. 8A-B illustrate two embodiments of golf club heads 800 having achannel 850 that operates as a flexible boundary structure. The twoembodiments are similarly designed with the exception of the orientationof the channel 850 and the resultant variation in the thickness, T2, ofthe second hinge region of each embodiment. The club head embodimentshown in FIG. 8A includes a second hinge region thickness T2 that issubstantially smaller/thinner than the second hinge region thickness T2of the embodiment shown in FIG. 8B. In some embodiments of the clubheads described herein, the second hinge region thickness T2 may be fromabout 0.5 mm to about 5.0 mm, such as from about 1.0 mm to about 2.5 mm,such as from about 1.2 mm to about 2.0 mm. In one embodiment, the secondhinge region thickness T2 is about 1.5 mm.

Table 5 below lists several exemplary values for the forward soleminimum thickness T_(FS), sole bar maximum thickness T_(SB), and theratio of T_(FS)/T_(SB) for several examples of clubheads that include achannel according to the embodiments described herein.

TABLE 5 Loft T_(FS) (mm) T_(SB) (mm) T_(FS)/T_(SB) Ex. 1 20-21° 0.5-5.04.0-40 0.04-0.50 (4I) 0.8-3.0 5.0-30 0.05-0.40 1.0-2.5 7.0-25 0.06-0.35Ex. 2 26-28° 0.5-5.0 4.0-40 0.04-0.50 (6I) 0.8-3.0 5.0-30 0.05-0.401.0-2.5 7.0-25 0.06-0.35

Returning again to FIGS. 2A-C, the channel 250 shown in the illustratedembodiment includes a forward channel wall 252 that is generallyparallel to the striking face 210, and that is also generally parallelto the rear channel wall 254. As a result, the channel width W1 issubstantially constant over the depth of the channel. In an alternativeembodiment, shown in FIG. 9, a club head 900 includes a channel 950having a forward channel wall 952, rear channel wall 954, and upperchannel wall 956. The forward channel wall 952 and rear channel wall 954are not parallel to one another, defining an included angle θ that maybe from slightly greater than 0° to about 25° or more.

3. Channel/Slot Profile Shapes and Orientations

In each of the embodiments described above, the channel is defined byforward, rear, and upper walls, and has a channel opening that is formedon the sole portion of the club head. Accordingly, except for thechannel opening, each of the channels described above is closed at itsforward, rear, and upper ends. In alternative embodiments, instead of aclosed channel, a channel may be provided having one or more openingsthat extend through one or more of the channel walls, and/or a slothaving no upper wall extends fully through the sole portion (or otherportion) of the club head in which it is located.

For example, in the embodiments shown in FIGS. 17A-B and 18A-C, a cavityback iron golf club head 1700 includes a channel 1750 that is defined inpart by a forward wall 1752, rear wall 1754, and upper wall 1756. Theclub head also includes a top line 1706, a striking face 1710, a forwardportion of the sole 1744, and a sole bar 1735, as described in relationto the embodiments described above. Moreoever, in alternativeembodiments (not shown in FIGS. 17A-B and 18A-C), the club head 1700 maycomprise a hollow iron (see, e.g., FIGS. 1C and 1E).

One or more cutouts or windows 1794 are provided on the forward wall1752 of the channel. See, e.g., FIGS. 18A-B. Each window 1794 providesincreased flexibility to the forward channel wall 1752, therebyincreasing the capability of the flexible boundary structure (FBS)provided by the channel 1750 to flex or deflect and to thereby provide adesired improvement in the performance of the golf club head. In theembodiments shown, the forward wall 1752 includes three cutouts orwindows 1794 that are generally equally spaced along the heel-to-toelength of the forward wall 1752. In alternative embodiments, fewer(e.g., one or two) or more (e.g., four or more) cutouts or windows 1794may be provided.

Although the example windows 1794 have an oblong shape, other shapes(e.g., round, oval, elliptical, triangular, square, rectangular,trapezoidal, etc.) are also possible. Turning to FIG. 18C, in theexample shown, a representative cutout or window 1794 has a length L_(w)which corresponds to the distance between the toeward-most andheelward-most ends of the window 1794, and a height H_(w) thatcorresponds to the distance between the crownward-most and soleward-mostends of the window 1794. The length L_(w) may be from about 1 mm to asmuch as the length L1 of the channel 1750, such as up to about 85 mm(e.g., in an embodiment that includes only a single window 1794). In theembodiments shown in FIGS. 18A-B, in which the forward wall includesthree windows 1794, the windows each have a length L_(w) of from about 3mm to about 18 mm, such as from about 6 mm to about 15 mm, such as fromabout 8 mm to about 12 mm. The height H_(w) may be from about 0.5 mm toas much as the height H1 of the channel 1750, such as up to about 25 mm.In the embodiments shown in FIGS. 18A-B, the windows each have a heightH_(w) of from about 0.5 mm to about 15 mm, such as from about 1 mm toabout 12 mm, such as from about 1.5 mm to about 8 mm.

Although not shown in the drawings, in alternative embodiments, one ormore windows or cutouts may be formed through the channel rear wall 1754and extending through the sole bar 1735, with an exit port provided on arearward-facing surface of the club head.

Turning to FIGS. 10A-B, in another example, a cavity back iron club head1000 includes a slot 1050 that extends fully through the sole 1008 intothe recess 1034 at the back portion of the club head. In an alternativeembodiment (not shown in FIGS. 10A-B), a hollow iron (see, e.g., FIG.1C) may include a slot that extends fully through the sole and into theinterior cavity of the club head.

The embodiment shown in FIG. 10A also shows a slot 1050 with an opening1058 that has a non-straight, curved shape when viewing the sole of theclub head. In other embodiments, the slot 1050 may be straight or mayhave a curved shape that is different from the embodiment shown in FIG.10A, several of which are described below. In the example shown, theslot opening 1058 is continuous and includes a first curved region 1070and a second curved region 1072. Each of the first and second curvedregions 1070, 1072 defines a generally semi-circular shape. The firstcurved region 1070 has a peak 1070 a that represents a point at whichthe first curved region 1070 is nearest to the leading edge 1042, andthat is located on the toeward half of the club head 1000. The secondcurved region 1072 has a peak 1072 a that represents a point at whichthe second curved region 1072 is nearest to the leading edge 1042, andthat is located on the heelward half of the club head 1000. A centerconnecting region 1073 connects the first and second curved regions1070, 1072, and is typically centered at or near the 0 coordinate of theCG x-axis 105.

The slot 1050 is located rearward of the forward portion 1044 of thesole and forward of the sole bar 1035. The slot 1050 has a face to slotdistance, D1, that is variable over the length of the slot 1050 due tothe curvature of the first curved region 1070 and second curved region1072. In the embodiment shown in FIGS. 10A-B, the face to slot distancemay be comparable to the ranges for the face to channel distance D1 ofthe embodiments described above in relation to FIGS. 2A-H and FIGS.3A-B. The slot 1050 also has a slot length, L1, that may be comparableto the ranges for the channel lengths L1 of the embodiments describedabove in relation to FIGS. 2A-H and FIGS. 6A-B. The slot 1050 also has aslot width, W1, that may be comparable to the ranges for the channelwidths W1 of the embodiments described above in relation to FIGS. 2A-Hand FIGS. 4A-B. In addition, in the embodiment shown, the forwardportion 1044 of the sole may have a forward sole wall minimum thickness,T_(FS), that may be comparable to the ranges for the forward sole wallminimum thickness T_(FS) of the embodiments described above in relationto FIGS. 2A-H and FIGS. 8A-B.

In some alternative embodiments (not shown in the drawings), an ironclub head 1000 may include a slot 1050 that extends fully through thesole 1008, and the forward portion 1044 of the sole may have a forwardsole wall minimum thickness, T_(FS), that is larger than the ranges forthe forward sole wall minimum thickness T_(FS) of the embodimentsdescribed above in relation to FIGS. 2A-H and FIGS. 8A-B. For example,in these alternative embodiments, the forward sole wall minimumthickness, T_(FS), may be from about 5 mm to about 15 mm, such as fromabout 5 mm to about 12 mm, such as from about 5 mm to about 8 mm.

Turning next to FIGS. 19A-B and 20A-B, examples are shown of a cavityback iron golf club head 1900 having a sole slot 1950. The club headalso includes a top line 1906, a striking face 1910, a forward portionof the sole 1944, and a sole bar 1935, as described in relation to theembodiments described above. The slot 1950 defines a passage through thesole 1908 into the recess 1934 at the back portion of the club head1900. Moreover, in alternative embodiments (not shown in FIGS. 19A-B and20A-B), the club head 1900 may comprise a hollow iron (see, e.g., FIGS.1C and 1E), in which case the slot 1950 provides a passage through thesole 1908 into the internal cavity 120 of the club head. The term “rearvoid” as used herein shall refer to either or both of a recess 1934 of acavity back iron golf club head or an internal cavity 120 of a hollowgolf club head. In certain embodiments the recess 1934 may contain abadge, which may be adhesively attached to the rear surface of the face,or may be attached to another portion of the club head to form a portionof, or all of, the back wall 132. In certain cavity back embodiments thebadge is adhesively attached to the rear surface of the face and extendsover a portion of the sole bar or thickened rearward sole bar andconceal the filler material. The badge may contain an aperture throughwhich the filler material is inserted, or the badge may cover an openingused to insert the filler material.

The slot 1950 is located in the sole 1908, rearward of the forwardportion 1944 of the sole and forward of the sole bar 1935. The slot 1950has a face to slot distance, D1, that may be comparable to the rangesfor the face to channel distance D1 of the embodiments described abovein relation to FIGS. 2A-H and FIGS. 3A-B. The slot 1950 also has a slotlength, L1, that may be comparable to the ranges for the channel lengthsL1 of the embodiments described above in relation to FIGS. 2A-H andFIGS. 6A-B. The slot 1950 also has a slot width, W1, that may becomparable to the ranges for the channel widths W1 of the embodimentsdescribed above in relation to FIGS. 2A-H and FIGS. 4A-B. In addition,in the embodiment shown, the forward portion 1944 of the sole may have aforward sole wall minimum thickness, T_(FS), that may be comparable tothe ranges for the forward sole wall minimum thickness T_(FS) of theembodiments described above in relation to FIGS. 2A-H and FIGS. 8A-B.

Cross-sectional views of the club head show a profile of the shape ofthe slot 1950 at a central region of the club head. As shown, forexample, in FIGS. 19A-B and 20A-B, the sole bar 1935 includes anoverhang member 1996 that extends into the space above the mouth of theslot 1950. In the FIG. 19A-B embodiment, the overhang member 1996extends over a substantial portion of the height of the forward-facingportion of the sole bar 1935, whereas in the FIG. 20A-B embodiment, theoverhang member 1996 comprises a narrow ledge extending from theforward-facing portion of the sole bar 1935 above the mouth of the slot1950. In some embodiments, the location and weight of the overhangmember 1996 may provide a desirable forward shift of the CG relative toa club head that does not include the overhang member 1996. In otherembodiments, the overhang member 1996 may provide a backstop that servesto partially trap or retain a viscous filler material that is injectedor otherwise inserted into the slot 1950 during manufacture of the clubhead, as described in more detail below.

The overhang member 1996 and slot 1950 define a non-linear passagethrough the sole 1908 and into the rear void of the club head, such asinto the recess 1934 at the back portion of the club head 1900 (for acavity back iron club head), or through the sole 1908 into the internalcavity 120 of the club head (for a hollow iron club head). Thenon-linear passage may be defined by the axial path 1998 illustrated inFIGS. 19B and 20B. The axial path 1998 represents an imaginary linecomprising a summation of the midpoints of lines representing theshortest distances between all points on the internal surfaces of theforward sole portion 1944 and rear surface of the striking plate 1910 ona forward side of the club head and opposed points on the internalsurfaces of the sole bar 1935 (including the overhang member 1996) on arearward side of the club head, for a given cross-section such as thatshown in FIGS. 19B and 20B.

In the embodiments shown in FIGS. 19B and 20B, the non-linear axial path1998 includes at least a lower path region 1998 a passing through themouth of the slot 1950, the lower path region 1998 a having an axialdirection that is generally parallel to the face plane 125, anintermediate path region 1998 b that is axially directed generallyperpendicular to the face plane 125, and an upper path region 1998 cthat is axially directed generally parallel to the face plane 125. Forexample, in some embodiments, the lower path region 1998 a includes aportion having a length of at least about 1 mm that is within about 30°of being parallel to the face plane 125, such as within about 20° ofbeing parallel to the face plane 125, such as within about 15° of beingparallel to the face plane 125. In some embodiments, the intermediatepath region 1998 b includes a portion having a length of at least about1 mm that is within about 30° of being perpendicular to the face plane125, such as within about 20° of being perpendicular to the face plane125, such as within about 15° of being perpendicular to the face plane125. In some embodiments, the upper path region 1998 c includes aportion having a length of at least about 1 mm that is within about 30°of being parallel to the face plane 125, such as within about 20° ofbeing parallel to the face plane 125, such as within about 15° of beingparallel to the face plane 125.

Turning next to FIGS. 11A-H, several examples of sole channel or soleslot profiles are shown. In each example, a club head 1100 includes aslot 1150 that extends over a portion of the sole 1108 of the club head.In the embodiment shown in FIG. 11A, the slot 1150 is a straight slothaving an orientation, shape, and size that is comparable to the channelprofile examples described above in relation to FIGS. 2A-C. In theembodiment shown in FIG. 11B, the slot 1150 has a shape of a singlecontinuous curve 1174 having a toe side end 1174 a, a heel side end 1174b, and a single peak 1174 c that is generally located at a pointcorresponding with the 0 coordinate of the CG x-axis 105 and/orcorresponding with the CG x-axis coordinate of the ideal impact location101 (see FIG. 1A). Similarly, in the embodiment shown in FIG. 11C, theslot 1150 has a shape of a single continuous curve 1174 having a toeside end 1174 a, a heel side end 1174 b, and a single peak 1174 c thatis generally located at a point corresponding with the 0 coordinate ofthe CG x-axis 105 and/or corresponding with the CG x-axis coordinate ofthe ideal impact location 101 (see FIG. 1A). In the FIG. 11B embodiment,the single peak 1174 a is arched toward the front portion 1130 of theclub head, i.e., the distance of the single peak 1174 a to the nearestportion of the leading edge 1142 is less than the distance of each ofthe toe side and heel side ends 1174 a, 1174 b to the nearest portionsof the leading edge 1142. In the FIG. 11C embodiment, the single peak1174 a is arched toward the back portion 1128 of the club head, i.e.,the distance of the single peak 1174 a to nearest portion of the leadingedge 1142 is greater than the distance of each of the toe side and heelside ends 1174 a, 1174 b to the nearest portions of the leading edge1142.

In the embodiment shown in FIG. 11D, the slot 1150 is a continuouscurved slot having an orientation, shape, and size that is comparable tothe examples described above in relation to FIGS. 10A-B, including afirst curved region 1170, a second curved region 1172, and a centerconnecting region 1173. The club head embodiment shown in FIG. 11Fincludes a slot 1150 having a first curved region 1170 and a secondcurved region 1172, but the slot does not include a center connectionregion. Instead, the slot 1150 shown in FIG. 11F is non-continuous,having two separate sections the first curved region 1170 and secondcurved region 1172. Finally, the club head embodiment shown in FIG. 11Eincludes a slot 1150 that is also non-continuous, comprising a firststraight region 1176 and a second straight region 1178 that are separateand not connected to each other.

In the embodiment shown in FIG. 11G, a club head 1100 includes a single,continuous, straight slot 1150 that extends over a substantial portionof the length of the sole 1108, extending generally from the heelportion 1102 to the toe portion 1104. The slot 1150 has a skewed ornon-parallel orientation relative to the leading edge 1142. In theembodiment shown, the distance from the toe side end 1150 a of the slotto the leading edge 1142 is less than the distance from the heel sideend 1150 b of the slot to the leading edge 1142.

In the embodiment shown in FIG. 1111, a club head 1100 includes asingle, continuous slot 1150 that includes a main portion 1180 that issubstantially parallel with the leading edge 1142 of the club head, anda secondary portion 1182 near the heel region 1102 that is oriented atan angle away from the leading edge 1142.

Similarly, in FIG. 11I, a club head 1100 includes a single, continuousslot 1150 that includes a main portion 1180 that is substantiallyparallel with the leading edge 1142 of the club head, a heel reliefportion 1183 and a toe relief portion 1184. In the embodiment shown,each of the heel relief portion 1183 and toe relief portion 1184 isjoined with the main portion 1180 of the slot by a radius region 1185that provides a transition from the leading edge parallel alignment ofthe main portion 1180 to the rearwardly-directed alignment of the heelrelief portion 1183 and toe relief portion 1184. As shown, the heelrelief portion 1183 is aligned generally rearward from the main portion1180, defining a relief angle γ which may be from about 90° to about150°. Similarly, the toe relief portion 1184 is aligned generallyrearward from the main portion 1180, defining a relief angle β which maybe from about 90° to about 150°. In some embodiments, the relief anglesγ and β are equal or substantially the same, while in other embodimentsthe relief angles γ and β are different. In some embodiments, the slotwidth W1 of one or both of the heel relief portion 1183 and/or the toerelief portion 1184 may be larger than the slot width W1 of the mainportion 1180, as shown for example in FIG. 11I.

In FIG. 11J, a club head 1100 includes a single, continuous slot 1150that includes a main portion 1180 that is substantially parallel withthe leading edge 1142 of the club head, a heel relief portion 1186 and atoe relief portion 1187. Each of the heel relief portion 1186 and toerelief portion 1187 comprises a widened region of the slot 1150, i.e.,the slot widths W1 of the slot 1150 in the regions of the heel reliefportion 1186 and toe relief portion 1187 are larger than the width W1 ofthe slot in the main portion 1180. In some embodiments, the ratio of theslot widths W1 of one or both of the heel relief portion 1186 and/or thetoe relief portion 1187 to the slot width W1 of the main portion 1180may be from about 1.1 to about 5, such as from about 1.1 to about 3,such as from about 1.1 to about 2.

In each of the foregoing embodiments that include a slot 1150 formed inthe sole 1108 of the club head, it is further advantageous to providerounded or tapered edge contours in order to provide stress relief andto enhance the durability of the club head. For example, in theembodiments shown in FIGS. 11I and 11J, it is advantageous toincorporate rounded corners and edges in the heel and toe reliefportions, where stress may be concentrated.

It should be noted that each of the sole slot profile embodiments shownin FIGS. 11A-J may be applied in the design of a sole channel as aflexible boundary structure on a club head. In those embodiments, thesole channel will include a forward wall, rear wall, and upper wall inthe manner described above in relation to FIGS. 2A-C.

4. Alternative Channel/Slot Locations

Several of the club head embodiments described above include one or moreflexible boundary structures located on the sole portion of the clubhead. In other, alternative embodiments, a flexible boundary structuremay be included on other portions of the club head. For example, in anembodiment shown in FIG. 12A, a club head 1200 includes a flexibleboundary structure in the form of a channel 1250 located at a toe region1204 of the club head. The club head 1200 may be either a cavity backconstruction having a recess 1234, or the club head 1200 may be a hollowconstruction having an interior cavity 1220. The channel 1250 is astraight, continuous channel that is generally parallel to the edge ofthe striking face 1210. The channel 1250 extends into a relatively thickperimeter weighting portion in the toe region 1204 of the club head. Inthe embodiment shown, the channel 1250 has a channel length, L1, achannel width, W1, and a channel depth, D1.

In an alternative embodiment, the club head 1200 may include a slotlocated at or along the toe region 1204, rather than the channel 1250shown in FIG. 12A. In the alternative embodiment, the slot extendsthrough the toe region 1204 of the club head and into the recess 1234(in the case of a cavity back club head) or the interior cavity 1220 (inthe case of a hollow club head). The slot may have a slot length L1 anda slot width W1.

In still other embodiments, a slot, channel, or other flexible boundarystructure may be located at the heel portion 102 (see FIGS. 1A-D), thetop line portion 106, on the striking face 110, or at another portion ofthe club head. For example, in an embodiment shown in FIG. 12B, a clubhead 1200 includes a flexible boundary structure in the form of achannel 1250 located at a heel region 1202 of the club head. Further, inan embodiment shown in FIG. 12C, a club head 1200 includes a flexibleboundary structure in the form of a channel 1250 located on the sole1208 and extending or “wrapped” around to the toe region 1204 and heelregion 1202. In those examples having a slot or a channel, the slot orchannel profile may be one of the profiles shown, for example, in FIGS.11A-H, or another profile, shape, or orientation.

In still other embodiments, a plurality of flexible boundary structuresmay be included at separate locations on the club head. For example,another club head embodiment is shown schematically in FIG. 13, in whicha first channel 1350 a is located in the toe region 1304, and a secondchannel 1350 b is located in the heel region 1302. In some embodiments,one or both of the first channel 1350 a and second channel 1350 b mayextend onto the sole region 1308 and wrap around the club head into thetoe region 1304 and/or heel region 1302, respectively. In still otherembodiments, one or both of the first channel 1350 a and second channel1350 b may be located fully within the toe region 1304 and/or heelregion 1302, respectively.

5. Channel Depth Profiles

In FIGS. 2A-C, the club head 200 includes a channel 250 that has aconstant depth, H1, over the full length of the channel. As noted abovein the discussion of the embodiments shown in those figures, in someembodiments, the channel depth H1 may be from about 5.0 mm to about 25.0mm, such as from about 6.0 mm to about 14.5 mm, such as from about 8.5mm to about 13.0 mm. In one embodiment, the channel depth H1 is about10.5 mm. In other, alternative embodiments, a club head may have achannel having a non-constant depth in order to achieve desiredperformance objectives.

For example, several club head embodiments are shown in FIGS. 14A-C.Each of the illustrated club heads includes a channel 1450 located onthe sole 1408 of the club head and extending into a sole bar (not shown)provided on the club head. For clarity, a projection of the depthprofile of each of the channels is represented schematically by thedashed lines projected on the striking face 1410 of the illustratedembodiments, with it being understood that the channel 1450 is notactually visible on the striking face 1410 of an actual club head. Theprojected depth profiles are intended to illustrate the depth and shapeof the channel 1450 within the sole bar of the club head.

The embodiment shown in FIG. 14A includes a channel 1450 having asubstantially constant depth, H1 over the full heel-side to toe-sidelength of the channel. The embodiments shown in FIGS. 14B-C, however,include channels 1450 having a non-constant depth profile. For example,the FIG. 14B embodiment includes a channel 1450 having a toe-side depth,Ht, a heel-side depth, Hh, and a center depth, Hc, that satisfy the twoinequalities: (1) Ht>Hc, and (2) Hh>Hc. On the other hand, the FIG. 14Cembodiment includes a channel 1450 having a toe-side depth, Ht, aheel-side depth, Hh, and a center depth, Hc, that satisfy the twoinequalities: (1) Ht<Hc, and (2) Hh<Hc.

In the embodiment shown in FIG. 14B, the peak or largest value for thedepth, Ht, of the channel 1450 on the toe-side portion of the channel islocated at the toe-side end of the channel, and the peak or largestvalue for the depth, Hh, of the channel 1450 on the heel-side portion ofthe channel is located at the heel-side end of the channel. In addition,the depth, Hc, of the channel at the center of the channel is a minimumdepth over the full-length of the channel. The channel depth, H1,gradually increases linearly moving in each direction from the center ofthe channel, toward the toe region 1404 and toward the heel region 1402.In other embodiments, the peak values for the toe-side depth, Ht, and/orheel-side depth, Hh, may be located between the center of the channeland the toe-side and heel-side ends of the channel, respectively. Inaddition, in some embodiments, the channel depth profile may benon-linear as it progresses from the center of the channel to the endsof the channel.

In the embodiment shown in FIG. 14C the minimum value for the depth, Ht,of the channel 1450 on the toe-side portion of the channel is located atthe toe-side end of the channel, and the minimum value for the depth,Hh, of the channel 1450 on the heel-side portion of the channel islocated at the heel-side end of the channel. In addition, the depth, Hc,of the channel at the center of the channel is a maximum depth over thefull-length of the channel. The channel depth, H1, gradually decreaseslinearly moving in each direction from the center of the channel, towardthe toe region 1404 and toward the heel region 1402. In otherembodiments, the minimum values for the toe-side depth, Ht, and/orheel-side depth, Hh, may be located between the center of the channeland the toe-side and heel-side ends of the channel, respectively. Inaddition, in some embodiments, the channel depth profile may benon-linear as it progresses from the center of the channel to the endsof the channel.

6. Multiple Channel Design

Turning next to FIGS. 15A-B, an embodiment of a club head 1500 includesa first channel 1550 and a second channel 1551 located in a sole bar1535 of the club head. The first channel 1550 is similar to the channeldescribed above in relation to the embodiments shown in FIGS. 2A-C,having a channel to face distance, D1, a first channel width, W1, afirst channel depth, H1, and a first channel length, L1. The forwardwall 1552 of the first channel defines a first hinge region 1560 havinga first hinge region thickness, T1, and a second hinge region 1562having a second hinge region thickness, T2. The forward portion 1544 ofthe sole defines a wall having a forward sole thickness, T_(FS). Thefirst channel 1550 further includes a rear wall 1554 and upper wall1556. A first channel opening 1558 is located on the sole region 1508 ofthe club head.

The second channel 1551 is located immediately rearward of (i.e., awayfrom the striking face 1510 from) the first channel 1550, and is definedby the first channel rear wall 1554, a second channel rear wall 1555,and a second channel lower wall 1557. A second channel opening 1559 islocated on the upper surface of the sole bar 1535. The second channel1551 has a second channel width, W2, a second channel depth, H2, and asecond channel length, L2. The second channel width, W2, is measuredusing substantially the same method used to measure the first channelwidth, W1, adapted based upon the relative orientation of the secondchannel. The second channel depth, H2, is the vertical distance betweena first horizontal plane corresponding with the second channel opening1559 and a second horizontal plane that contains the lowermost point ofthe interior of the second channel 1551. The second channel length L2 isa measure of the distance on the sole bar 1535 of the club head betweenthe toeward-most point of the second channel 1551 and the heelward-mostpoint of the second channel 1551, without taking into account anycurvature of the channel 1551. The rear wall 1554 of the first channel,which corresponds to a forward wall of the second channel 1551, definesa third hinge region 1564 having a third hinge region thickness, T3, anda fourth hinge region 1562 having a fourth hinge region thickness, T4.

The first channel 1550 and second channel 1551 are separated by achannel separation distance, D_(SEP), that is determined as follows. Afirst channel centerline 1529 a and second channel centerline 1529 b areconstructed in the manner described above in relation to the channelcenterline shown in FIGS. 2D-E. An imaginary reference line 1522 isdrawn parallel to the ground plane 1511 at a height of 5 mm above theground plane. The distance between the points of intersection of thereference line 1522 and the first channel centerline 1529 a and secondchannel centerline 1529 b defines the channel separation distanceD_(SEP).

In some embodiments, the first channel centerline 1529 a and secondchannel centerline 1529 b are parallel to one another. In otherembodiments, the first channel centerline 1529 a and second channelcenterline 1529 b are oriented such that they define a channelcenterline angle α therebetween. In some embodiments, the first channelcenterline 1229 a has an orientation that is steeper (i.e., closer tovertical) than the orientation of the second channel centerline 1229 b.In those embodiments, the channel centerline angle α is oriented“upward” and may have a value ranging from slightly greater than 0° toslightly less than 90°, such as between about 1° and about 15°. In someother embodiments, the first channel centerline 1229 a has anorientation that is shallower (i.e., closer to horizontal) than theorientation of the second channel centerline 1229 b. In thoseembodiments, the channel centerline angle α is oriented “downward” andmay have a value ranging from slightly greater than 0° to slightly lessthan 90°, such as between about 1° and about 15°.

Table 6 below lists several exemplary values for the channel separationdistance D_(SEP) and channel centerline angle α for several examples ofclubheads that include a dual channel design according to theembodiments described herein.

TABLE 6 Loft D_(SEP) (mm) α (Range) Ex. 1 20-21° 1.5-8.0 0 to 45 deg(4I) 2.0-6.0 0 to 45 deg 2.5-4.0 0 to 45 deg Ex. 2 26-28° 1.5-8.0 0 to45 deg (6I) 2.0-6.0 0 to 45 deg 2.5-4.0 0 to 45 deg

FIG. 15C shows another embodiment of a club head 1500 that includes afirst channel 1550, a second channel 1551, and a third channel 1553located in a sole bar 1535 of the club head. The first channel 1550 andsecond channel 1551 are similar to the channels described above inrelation to the embodiments shown in FIGS. 15A-B, having channel to facedistances, D1 and D2, channel widths, W1 and W2, channel depth, H1 andH2, and channel lengths, L1 and L2. The forward wall 1552 of the firstchannel defines a first hinge region 1560 having a first hinge regionthickness, T1, and a second hinge region 1562 having a second hingeregion thickness, T2. The forward portion 1544 of the sole defines awall having a forward sole thickness, T_(FS). The first channel 1550further includes a rear wall 1554 and upper wall 1556. A first channelopening 1558 is located on the sole region 1508 of the club head.

The third channel 1553 is located immediately rearward of (i.e., awayfrom the striking face 1510 from) the second channel 1551, and isdefined by the second channel rear wall 1555, a third channel rear wall1568, and a third channel upper wall 1569. A third channel opening 1571is located on the lower surface of the sole bar 1535. The third channel1553 has a third channel width, W3, a third channel depth, H3, and athird channel length, L3, each of which is measured using substantiallythe same method used to measure the corresponding parameters of thefirst channel.

7. Fillers, Damping, Vibration

In the club head embodiments described above, the described flexibleboundary structures include channel and slot designs and/or the overhangmember define voids or spaces within the club head. In some embodiments,these voids or spaces are left unfilled. In others, such as theembodiments illustrated in FIGS. 2H and 19C, a filler material 223 maybe added into a portion of the recess 1934, the internal cavity 120, thevoid created under a portion of the overhang member 1996, the channel,slot, or other flexible boundary structure. One or more fillers may beadded to achieve desired performance objectives, including preventingunwanted materials (e.g., water, grass, dirt, etc.) from entering thechannel or slot, or obtaining desired changes to the sound and feel ofthe club head by damping vibrations that occur when the club headstrikes a golf ball.

Examples of materials that may be suitable for use as a filler to beplaced into a slot, channel, or other flexible boundary structureinclude, without limitation: viscoelastic elastomers; vinyl copolymerswith or without inorganic fillers; polyvinyl acetate with or withoutmineral fillers such as barium sulfate; acrylics; polyesters;polyurethanes; polyethers; polyamides; polybutadienes; polystyrenes;polyisoprenes; polyethylenes; polyolefins; styrene/isoprene blockcopolymers; hydrogenated styrenic thermoplastic elastomers; metallizedpolyesters; metallized acrylics; epoxies; epoxy and graphite composites;natural and synthetic rubbers; piezoelectric ceramics; thermoset andthermoplastic rubbers; foamed polymers; ionomers; low-density fiberglass; bitumen; silicone; and mixtures thereof. The metallizedpolyesters and acrylics can comprise aluminum as the metal. Commerciallyavailable materials include resilient polymeric materials such asScotchweld™ (e.g., DP105™) and Scotchdamp™ from 3M, Sorbothane™ fromSorbothane, Inc., DYAD™ and GP™ from Soundcoat Company Inc., Dynamat™from Dynamat Control of North America, Inc., NoViFlex™ Sylomer™ fromPole Star Maritime Group, LLC, Isoplast™ from The Dow Chemical Company,Legetolex™ from Piqua Technologies, Inc., and Hybrar™ from the KurarayCo., Ltd. Certain embodiments utilize non-expanding foam such asinjection foam, urethane, two part foam, or chemical initiated expansionfoam. Other embodiments may incorporate encapsulated particles having aparticle size between about 2 μm and about 90 μm.

In some embodiments the filler material has a density between about 0.03g/cc and about 0.19 g/cc. In yet another embodiment the filler materialmay have a modulus of elasticity ranging from about 0.001 GPa to about25 GPa, and/or a durometer ranging from about 5 to about 95 on a Shore Dscale. In other examples, gels or liquids can be used, and softermaterials which are better characterized on a Shore A or other scale canbe used. The Shore D hardness on a polymer is measured in accordancewith the ASTM (American Society for Testing and Materials) test D2240.In a further embodiment the filler material has a hardness range ofabout 15-85 Shore OO hardness or about 80 Shore OO hardness or less.

In some embodiments, a solid filler material may be press-fit oradhesively bonded into a portion of the aforementioned voids, recesses,cavity, or spaces within the club head, slot, channel, or other flexibleboundary structure. In other embodiments, a filler material may poured,injected, or otherwise inserted into a portion of the aforementionedvoids, recesses, cavity, or spaces within the club head, slot or channeland allowed to cure in place, forming a sufficiently hardened orresilient outer surface. In still other embodiments, a filler materialmay be placed into a portion of the aforementioned voids, recesses,cavity, or spaces within the club head, slot or channel and sealed inplace with a resilient cap or other structure formed of a metal, metalalloy, metallic, composite, hard plastic, resilient elastomeric, orother suitable material.

In some embodiments, the portion of the filler 223 or cap that isexposed within the channel 250 has a generally convex shape and isdisposed within the channel such that the lowermost portion of thefiller 223 or cap is displaced by a gap, DF, below the lowermost surfaceof the immediately adjacent portions of the body of the clubhead 200.(See, e.g., FIG. 211). The gap DF is preferably sufficiently large toprevent excessive wear and tear on the filler 223 or cap that is exposedwithin the channel due to striking the ground or other objects. In thisway, the filler 223 or cap is not exposed to excessive wear due tocontact with the ground during a swing that would otherwise occur if thefiller 223 or cap were located flush with the adjacent portions of theclubhead body.

In the embodiment shown in FIG. 19C, the club head 1900 includes a slot1950 and an overhang 1996. Whereas the slot 1950 provides a passagethrough the sole 1908 and into a rear void (e.g., a recess 1934 orinternal cavity 120) of the club head, the overhang 1996 extends fromthe sole bar 1935 toward the rear surface of the striking plate therebycreating a recess under the overhang 1996, and may partially blocks thepassage. In certain embodiments, the overhang 1996 serves as a backstopto partially trap or retain a viscous filler material 223 that isinjected or otherwise inserted into the aforementioned voids, recesses,cavity, spaces, or slot 1950 during manufacture of the club head.Accordingly, during manufacture, the viscous filler material 223 may beinjected through the slot 1950 or an aperture in the club head 1900.When injected through the slot 1950 the viscous filler material 223 may,encounter the overhang 1996 which will stop the generally upward flow ofthe filler material 223 and redirect the flow generally toward thestriking face 1910, thereby reducing the amount of filler material 223needed to seal the slot 1950. In certain embodiments the filler material223 may extend into the recess formed under the overhang member 1996,extend between the overhang member 1996 and the rear surface of theface, and/or fill all of, or a portion of, the cavity recess 1934 or theinternal cavity 120.

8. Golf Club Sets

Referring now to FIG. 16, there is illustrated a golf club set 1600. Thegolf club set 1600 may include one or more types of golf club heads1604, including cavity back, muscleback, blades, hollow clubs or othertypes of club heads typically used as part of a set. The golf club set1600 may have varying performance characteristics between clubs. Forexample, shafts 1602 may vary in length, swing weight may vary, and oneor more of the performance characteristics noted above may vary. As oneexample, at least a portion of the golf clubs of set 1600 may includehollow clubs. Individual hollow clubs may include hollow areas that varyin volume. Furthermore, hollow areas may be filled with foam, polymer orother types of materials, and the particular type of filler materialsmay vary from club to club. Additionally, the club types within set 1600may vary, such as by including some hollow clubs, some cavity back clubsand some muscleback clubs within one set.

In several embodiments of the golf club set 1600, at least one of thegolf clubs included in the set 1600 has a club head 1604 having aflexible boundary structure, such as a slot, a channel, or otherstructure, whereas at least one other of the golf clubs included in theset 1600 has a club head 1604 that does not have a flexible boundarystructure. For example, in some embodiments, at least one of the golfclubs included in the set 1600 has a club head 1604 having a slot orchannel such as one or more of the club head embodiments describedherein in reference to FIGS. 2A-H through 15A-C, and at least one otherof the golf clubs included in the set 1600 does not have a flexibleboundary structure. In some embodiments, a set of 8 or more golf clubsmay include up to 2, up to 3, up to 4, up to 5, up to 6, or up to 7 golfclubs with club heads having a flexible boundary structure, with theremainder having no flexible boundary structure.

Tables 7A through 7D illustrate four particular embodiments of golf clubsets 1600 having performance characteristics that vary between clubswithin the set. However, it is worthwhile to note that these are justfour embodiments and the claimed subject matter is not limited in thisrespect.

TABLE 7A Iron # 3 4 5 6 7 8 9 PW Loft (Range) 17-19° 20-21° 23-24°26-28° 30-32° 34-36° 39-41° 44-46° Head Constr. Cavity- Cavity- Cavity-Cavity- Cavity- Cavity- Cavity- Cavity- back back back back back backback back FBS Y Y Y N N N N N FBS Type Channel Channel Channel FBSLocation Sole Sole Sole FBS Shape FIGS. FIGS. FIGS. 2A-C 2A-C 2A-C

TABLE 7B Iron # 3 4 5 6 7 8 9 PW Loft (Range) 17-19° 20-21° 23-24°26-28° 30-32° 34-36° 39-41° 44-46° Head Constr. Hollow Hollow HollowCavity- Cavity- Cavity- Cavity- Cavity- back back back back back FBS Y YY Y Y N N N FBS Type Channel Channel Channel Channel Channel FBSLocation Sole Sole Sole Sole Sole FBS Shape FIGS. FIGS. FIGS. FIGS.FIGS. 2A-C 2A-C 2A-C 2A-C 2A-C

TABLE 7C Iron # 4 5 6 7 8 9 PW AW SW LW Loft (Range) 20-21° 23-24°26-28° 30-32° 34-36° 39-41° 44-46° 49-51° 54-56° 59-61° Head Constr.Hollow Hollow Cav-back Cav-back Cav-back Cav-back Cav-back Cav-backCav-back Cav-back FBS Y Y Y Y Y Y Y Y N N FBS Type Channel ChannelChannel Channel Channel Channel Channel Channel FBS Location Sole SoleSole Sole Sole Sole Sole Sole FBS Shape FIGS. FIGS. FIGS. FIGS. FIGS.FIGS. FIGS. FIGS. 2A-C 2A-C 2A-C 2A-C 2A-C 2A-C 2A-C 2A-C

TABLE 7D Iron # 3 4 5 6 7 8 9 PW Loft (Range) 17-19° 20-21° 23-24°26-28° 30-32° 34-36° 39-41° 44-46° Head Constr. Hollow Hollow HollowCav-back Cav-back Cav-back Cav-back Cav-back FBS Y Y Y Y Y N N N FBSType Channel Channel Channel Channel Channel FBS Location Sole Sole SoleSole Sole FBS Shape FIGS. FIGS. FIGS. FIGS. FIGS. 2A-C 2A-C 2A-C 2A-C2A-C

As reflected in Tables 7A through 7D, there are unique compositions ofgolf clubs within a multi-club set, one or more of which include aflexible boundary structure (e.g., a channel) and one or more of whichdo not include a flexible boundary structure. (It should be understoodthat the golf club set may have fewer or more irons than set forth inTables 7A through 7D.) It is generally preferable to achieve aconsistent average gapping distance from club to club. In this way, thegolfer is provided with a full range of consistent and increasing clubshot distances so that the golfer can select a club or iron for thedistance required by a particular shot or situation. Typically, theaverage gapping distance from club to club in a set of irons for anaverage player is about 8-10 yards. As set forth herein, the uniqueinclusion of individual clubs having a flexible boundary structure withthose not having a flexible boundary structure from the LW to the 3-ironhelps provide for an average gapping distance for an average player ofabout 11-15 yards from club to club, respectively. In this respect, theembodiments herein provide consistency as well as an overall greaterrange of distances for the golfer.

Other parameters may contribute to overall greater gap distance in theset, and greater ball speed and distance for each individual iron. Theseparameters include shaft length, face thickness, face area, weightdistribution (and resultant club head moment of inertia (“MOI”) andcenter of gravity (“CG”) location), and others. In addition, still otherparameters may contribute to performance, playability, forgiveness orother features of golf clubs contained within the set. These parametersinclude topline thicknesses (and topline thickness progression withinthe set), swing weights, and sole widths. Descriptions of thecontributions of these parameters to the performance of golf clubswithin a set of golf clubs is provided in United States Published PatentApplication No. 2011/0159981, which is hereby incorporated by referencein its entirety.

9. Club Head Performance

The inventors of the club heads described herein investigated the effectof incorporating channels, slots, and other flexible boundary structuresinto the perimeter regions of iron type club heads. Iron golf club headdesigns were modeled using commercially available computer aidedmodeling and meshing software, such as Pro/Engineer by ParametricTechnology Corporation for modeling and Hypermesh by Altair Engineeringfor meshing. The golf club head designs were analyzed using finiteelement analysis (FEA) software, such as the finite element analysisfeatures available with many commercially available computer aideddesign and modeling software programs, or stand-alone FEA software, suchas the ABAQUS software suite by ABAQUS, Inc. Under simulation, models ofiron type golf club heads having flexible boundary structuresincorporated into perimeter regions of the club heads were observed toproduce relatively higher values of COR and CT when compared tosimilarly constructed golf club heads that do not include a flexibleboundary structure.

In addition, golf clubheads having channels were constructed todetermine the effect of incorporating a channel into the perimeterregions of the clubheads. COR measurements were taken of two golf clubheads. The first club head did not include a flexible boundarystructure. The second club head included a straight, continuous channellocated in the sole of the club head, and having the followingparameters set forth in Table 8:

TABLE 8 Face to channel distance (D1) 8.7 mm Clubhead depth (D_(CH))27.9 mm Channel width (W1) 1.5 mm Channel depth (H1) 12.3 mm First hingethickness (T1) 1.0 mm Second hinge thickness (T2) 1.0 mm Forward solemin thickness (T_(FS)) 2.0 mm Sole bar max thickness (T_(SB)) 15.3 mmChannel length (L1) 54 mm Sole Length (L_(B)) 82.2 mm Ratio D1/D_(CH)0.31 Ratio T_(FS)/T_(SB) 0.13 Ratio L1/L_(B) 0.66

The golf clubs were otherwise identical. COR testing was performed atseveral locations on the striking face of each of the clubheads, and thefollowing results were obtained:

TABLE 9 Without Channel With Channel Relative Relative Location CORLocation COR COR Gain Toe −10 mm −0.045 −10 mm −0.026 0.019 Toe −5 mm−0.017 −5 mm −0.004 0.013 ISL 0 −0.009 0 0.005 0.014 Heel 5 mm −0.015 5mm −0.004 0.011 Heel 10 mm −0.033 10 mm −0.014 0.019 Crown 5 mm −0.052 5mm −0.022 0.030 Crown 2.5 mm −0.011 2.5 mm 0.002 0.013 ISL 0 −0.009 00.005 0.014 Sole −2.5 mm −0.031 −2.5 mm −0.004 0.027 Sole −5 mm −0.045−5 mm −0.014 0.031

In Table 9, the location “ISL” refers to the ideal striking location.The references to locations at distances toward the “Toe” and “Heel”refer to horizontal distances within the striking face plane from theISL toward the toe and heel of the clubhead. The references to locationsat distances toward the “Crown” and “Sole” refer to distances toward thecrown and sole of the clubhead along a line defined by the intersectionof the striking face plane and a perpendicular vertical plane.Accordingly, the flexible boundary structure was responsible for anincrease in the COR of the club head of from about 0.11 to about 0.31,depending upon the location on the striking face of the clubhead.

In view of the many possible embodiments to which the principles of thedisclosed invention may be applied, it should be recognized that theillustrated embodiments are only preferred examples of the invention andshould not be taken as limiting the scope of the invention. It will beevident that various modifications may be made thereto without departingfrom the broader spirit and scope of the invention as set forth. Thespecification and drawings are, accordingly, to be regarded in anillustrative sense rather than a restrictive sense.

1-11. (canceled)
 12. An iron-type golf club head of claim, comprising:an iron-type body having a heel portion, a toe portion, a top-lineportion, a face portion having a variable face thickness varying from aminimum face thickness to a maximum face thickness, a sole portionextending rearwardly from a lower end of said face portion, and the bodydefines a cavity behind the face portion including a lower cavity regionwherein: the face portion includes an ideal striking location thatdefines the origin of a coordinate system in which an x-axis istangential to the face portion at the ideal striking location and isparallel to a ground plane when the body is in a normal addressposition, a y-axis extends perpendicular to the x-axis and is alsoparallel to the ground plane, and a z-axis extends perpendicular to theground plane, wherein a positive x-axis extends toward the heel portionfrom the origin, a positive y-axis extends rearwardly from the origin,and a positive z-axis extends upwardly from the origin; the face portiondefines a striking face plane that intersects the ground plane along aface projection line; the body includes a central region which extendsalong the x-axis from a location greater than about −25 mm to a locationless than about 25 mm, the sole portion contained within the centralregion includes a thinned forward sole region located adjacent to theface portion and a thickened rearward sole region located behind thethinned forward sole region, with the thinned forward sole regiondefining a wall having a minimum forward sole thickness T_(FS) and thethickened rearward sole region having a maximum sole bar thicknessT_(SB); at least one vertical section within the central region andparallel to the y-axis has (a) the minimum forward sole thickness T_(FS)no more than 3.0 mm and less than the maximum face thickness, (b) themaximum sole bar thickness T_(SB) at least 7.0 mm, and (c) a ratio ofthe minimum forward sole thickness T_(FS) to the maximum sole barthickness T_(SB) is 0.04-0.50: wherein the lower cavity region separatesthe thickened sole region from a rear surface of the face and the lowercavity region is at least partially defined by a rear surface of theface, the thinned forward sole region, and the thickened rearward soleregion.
 13. The iron-type golf club head of claim 12 further comprisinga back wall enclosing the cavity, wherein the back wall extends from afirst portion of the iron-type golf club head proximate the top-lineportion to a second portion of the iron-type golf club head proximatethe thickened sole region.
 14. The iron-type golf club head of claim 13,wherein the cavity is at least partially hollow.
 15. The iron-type golfclub head of claim 14, wherein the cavity is at least partially filledwith a filler material.
 16. The iron-type golf club head of claim 14,wherein the cavity is filled with a filler material.
 17. The iron-typegolf club head of claim 12, wherein the cavity includes a vibrationdampening insert, the vibration dampening insert contacts the rearsurface the face.
 18. The iron-type golf club head of claim 14, whereinthe cavity includes a vibration dampening insert, the vibrationdampening insert contacts the rear surface the face.
 19. The iron-typegolf club head of claim 13, wherein the back wall includes an apertureand a vibration dampening insert is installed into the cavity throughthe aperture, and the vibration dampening insert contacts the rearsurface the face.
 20. The iron-type golf club head of claim 13, whereinthe back wall includes an inner back wall surface that defines a portionof the cavity and forms a back wall thickness between an outer back wallsurface that defines an outer portion of the iron-type golf club head.21. The iron-type golf club head of claim 20, wherein the back wallthickness ranges between about 0.5 mm to about 4 mm.
 22. The iron-typegolf club head of claim 20, wherein the back wall thickness varies. 23.The iron-type golf club head of claim 12, wherein the variable facethickness is asymmetrical.
 24. The iron-type golf club head of claim 12,wherein the variable face thickness is asymmetrical such that thethickness of the face portion proximate to the thinned forward soleregion is less than the thickness of the face portion distal to thethinned forward sole region.
 25. The iron-type golf club head of claim12, wherein the cavity includes an undercut recess around a periphery ofthe iron-type golf club head.
 26. The iron-type golf club head of claim12, wherein the face portion includes a striking plate welded to theiron-type body and the striking plate is formed from a first steel alloyand the iron-type body is formed from a second steel alloy.
 27. Theiron-type golf club head of claim 15, wherein the first steel alloy is aprecipitation hardened stainless steel alloy and the second steel alloyis a carbon steel alloy.
 28. The iron-type golf club head of claim 15,wherein the first steel alloy is a chrome-molybdenum steel alloy and thesecond steel alloy is a carbon steel.
 29. The iron-type golf club headof claim 12, wherein the lower cavity region comprises a first lowercavity region located forward of the maximum sole bar thickness and asecond lower cavity region located rearward of the maximum sole barthickness.
 30. The iron-type golf club head of claim 21, wherein thelower cavity region comprises a first lower cavity region locatedforward of the maximum sole bar thickness and a second lower cavityregion located rearward of the maximum sole bar thickness.
 31. Theiron-type golf club head of claim 12, wherein the lower cavity regionhas a lower cavity width defined as a distance between the rear surfaceof the face and the thickened rearward sole region as measured along ay-axis, wherein the lower cavity width varies and decreases proximate tothe thinned forward sole region and increases distal to the thinnedforward sole region.